Patent ID: 7517424

Claim:
A method of forming a microchannel collimating array, comprising: tilting a substrate, which has a photoresist, with respect to a collimated irradiation beam to form a plurality of pedestals at an angle with respect to a substrate surface normal; patterning the photoresist with the collimated irradiation beam through a mask; forming the plurality of pedestals in the substrate by at least one of (i) selectively removing material between the plurality of pedestals or (ii) selectively depositing material; applying the elastic-sheet forming material to the substrate to form an elastic sheet; separating the elastic sheet with a plurality of voids from the substrate formed with the plurality of pedestals, such that a plurality of voids are left in the elastic sheet at the locations of the pedestals, the elastic sheet capable of stretching by 100% to 1000% and returning to original shape when released with substantially negligible permanent deformation.