Patent ID: 8444907

Claim:
A method for fabricating a substantially seamless pattern, comprising; a. providing a first portion of curable material between a substantially flexible first patterned mold and a substrate proximate a first nip point provided by at least one roller; b. passing the first portion of curable material, the first mold, and the substrate through the first nip point to spread the first portion of curable material by the first mold into a first layer of curable material over the substrate; c. curing the first layer of curable material to form a first cured portion; d. removing the first mold from the first cured portion; e. after step d., providing a second portion of curable material over at least a portion of the first cured portion between a substantially flexible second patterned mold and the substrate proximate a second nip point provided by the at least one roller; f. passing the second portion of curable material, the second mold, and the substrate through the second nip point to spread the second portion of curable material by the second mold into a second layer of curable material over the substrate; g. curing the second layer of curable material to form a second cured portion joined by a seam to the first cured portion; and h. removing the second mold from the second cured portion, wherein the seam between the first cured portion and the second cured portion has a dimension of less than about 5 micrometers, wherein step b. results in depletion of the first portion of curable material prior to the first mold and substrate exiting the first nip point so that the first portion of curable material tapers to depletion between the first mold and substrate, and wherein step e. results in adding the second portion of curable material to at least a portion of the depleted portion of the first cured portion so that upon completion of step h., the second portion of curable material substantially fills the tapered depletion to a pre-depletion thickness.