Manufacturing Miniature Structured Elements with Tool Incorporating Spacer Elements

摘要

A plurality of optical elements can be manufactured by replication. A replication tool can include a plurality of replication sections having negative structural features that define the shape of the plurality of optical elements and at least one first spacer portion. A replication material can be disposed between a substrate and the replication tool. The replication tool and the substrate can be moved so that a substantially flat surface portion of each first spacer portion rests against a layer of replication material remaining between the at least one first spacer portion and the substrate. The layer of replication material keeps the at least one first spacer portion spaced from the substrate. The replication material can be hardened to form the plurality of optical elements.