Abstract: A fly-cutting system is disclosed, and in particular one that comprises a dynamically-controllable actuator for controlling the position, orientation, or both position and orientation of a cutting element carried by a fly-cutting head. In certain embodiments, the actuator can adjust the position or orientation of a cutting element, or both, hundreds or thousands of times per second, enabling precise control over the shape of features formed by the cutting element in a surface of a workpiece.

Abstract: A light directing film includes a structured major surface with a plurality of microstructures extending along a first direction. Each microstructure has a first region and a second region different from the first region, a substantially constant height in the first region and a non-constant maximum height in the second region greater than the substantially constant height in the first region, and a same lateral cross sectional shape in the first region and the second region.

Abstract: A fly-cutting system is disclosed, and in particular one that comprises a dynamically-controllable actuator for controlling the position, orientation, or both position and orientation of a cutting element carried by a fly-cutting head. In certain embodiments, the actuator can adjust the position or orientation of a cutting element, or both, hundreds or thousands of times per second, enabling precise control over the shape of features formed by the cutting element in a surface of a workpiece.

Abstract: A fly-cutting system is disclosed, and in particular one that comprises a dynamically-controllable actuator for controlling the position, orientation, or both position and orientation of a cutting element carried by a fly-cutting head. In certain embodiments, the actuator can adjust the position or orientation of a cutting element, or both, hundreds or thousands of times per second, enabling precise control over the shape of features formed by the cutting element in a surface of a workpiece.

Abstract: A light directing film includes a structured major surface with a plurality of microstructures extending along a first direction. Each microstructure has a first region and a second region different from the first region, a substantially constant height in the first region and a non-constant maximum height in the second region greater than the substantially constant height in the first region, and a same lateral cross sectional shape in the first region and the second region.

Abstract: A light directing film includes a structured major surface with a plurality of microstructures extending along a first direction. Each microstructure has a first region and a second region different from the first region, a substantially constant height in the first region and a non-constant maximum height in the second region greater than the substantially constant height in the first region, and a same lateral cross sectional shape in the first region and the second region.

Abstract: Methods of fly-cutting a workpiece are disclosed, and in methods in which the position of a fly-cutting head or its associated cutting element is known as a function of time. Also disclosed are methods of forming features, such as grooves or groove segments, in a workpiece such as a cylindrical roll. The features may be provided according to one or more disclosed patterns. Articles made using tools machined in the manner described are also provided, such as polymeric film or sheeting that exhibit certain beneficial properties.

Abstract: Methods and systems for forming a displacement scale comprising TIR prisms on a substrate are described. A system for forming the displacement scale includes one or more rollers having a pattern of total internal reflection (TIR) prism features in negative relief. As the rollers are rotated, the scale is formed on the substrate. The rollers may also include pattern features in negative relief. Rotation of the rollers simultaneously forms the displacement scale and the pattern features on the substrate. The TIR prism features of the displacement scale may be oriented to provide measurement of one or more of lateral displacement, longitudinal displacement and angular displacement.

Abstract: A fly-cutting system is disclosed, and in particular one that comprises a dynamically-controllable actuator for controlling the position, orientation, or both position and orientation of a cutting element carried by a fly-cutting head. In certain embodiments, the actuator can adjust the position or orientation of a cutting element, or both, hundreds or thousands of times per second, enabling precise control over the shape of features formed by the cutting element in a surface of a workpiece.

Abstract: A fly-cutting system is disclosed, and in particular one that comprises a dynamically-controllable actuator for controlling the position, orientation, or both position and orientation of a cutting element carried by a fly-cutting head. In certain embodiments, the actuator can adjust the position or orientation of a cutting element, or both, hundreds or thousands of times per second, enabling precise control over the shape of features formed by the cutting element in a surface of a workpiece.

Abstract: Methods of fly-cutting a workpiece are disclosed, and in methods in which the position of a fly-cutting head or its associated cutting element is known as a function of time. Also disclosed are methods of forming features, such as grooves or groove segments, in a workpiece such as a cylindrical roll. The features may be provided according to one or more disclosed patterns. Articles made using tools machined in the manner described are also provided, such as polymeric film or sheeting that exhibit certain beneficial properties.

Abstract: Optical films having anti-Moiré and anti-wetout features are described, along with systems and methods for making these optical films. A master used to make optical films is formed using a single axis actuator cutting along a trajectory that is out of plane with the surface of the master. Movement of the cutting tool along the trajectory cuts grooves having variable depth and variable pitch into the surface. Prisms formed from the master have variable depth, variable height prisms that provide anti-wetout and anti-Moiré features.

Abstract: Optical films having anti-Moiré and anti-wetout features are described, along with systems and methods for making these optical films. A master used to make optical films is formed using a single axis actuator cutting along a trajectory that is out of plane with the surface of the master. Movement of the cutting tool along the trajectory cuts grooves having variable depth and variable pitch into the surface. Prisms formed from the master have variable depth, variable height prisms that provide anti-wetout and anti-Moiré features.

Abstract: An optical film for use in transparent displays, such as reflective LCDs. The optical film has three-dimensional, prismatic structures that reflect incoming light. The prismatic structures are configured so that the reflecting facets orient the reflected light in desired reflective light pattern. The pattern shape and intensity can be controlled by the shape and dimensions of the various reflecting facets. In one embodiment, the height of the prismatic structure varies along two dimensions of the structure.

Abstract: Optical films having anti-Moiré and anti-wetout features are described, along with systems and methods for making these optical films. A master used to make optical films is formed using a single axis actuator cutting along a trajectory that is out of plane with the surface of the master. Movement of the cutting tool along the trajectory cuts grooves having variable depth and variable pitch into the surface. Prisms formed from the master have variable depth, variable height prisms that provide anti-wetout and anti-Moiré features.

Abstract: Methods of fly-cutting a workpiece are disclosed, and in methods in which the position of a fly-cutting head or its associated cutting element is known as a function of time. Also disclosed are methods of forming features, such as grooves or groove segments, in a workpiece such as a cylindrical roll. The features may be provided according to one or more disclosed patterns. Articles made using tools machined in the manner described are also provided, such as polymeric film or sheeting that exhibit certain beneficial properties.

Abstract: Methods and systems for indicating the displacement of a flexible web are described. An elongated, flexible web includes an integral scale having scale features configured to modulate energy directed towards the web. A transport mechanism provides relative movement between the web relative to a transducer. The transducer detects energy modulated by the scale features and generates a signal indicting a continuous web displacement based on the modulated energy.

Abstract: A method for cutting a pattern in a work piece (50), wherein the pattern includes adjacent features (52,53) separated by a pitch spacing P. The method includes providing a cutting tool assembly (74) having a first tool shank with a first cutting tip (22) to create a first feature (52) in the work piece (50) and a second tool shank with a second cutting tip (23) to create a second feature (53) in the work piece (50), wherein a distance Y between the first cutting tip and the second cutting tip is equal to nP, and wherein n is an odd integer greater than 1. The work piece is rotated (C) with respect to the cutting tool assembly (74), and the cutting tool is advanced along a lateral direction (B) with respect to the rotating work piece (50), wherein the cutting tool (74) is advanced along the lateral direction a distance of 2P for each rotation of the work piece (50).

Abstract: A light directing film includes a structured major surface with a plurality of microstructures extending along a first direction. Each microstructure has a first region and a second region different from the first region, a substantially constant height in the first region and a non-constant maximum height in the second region greater than the substantially constant height in the first region, and a same lateral cross sectional shape in the first region and the second region.

Abstract: An approach for making a master tool used to fabricate optical films involves cutting a series of base structures. Modifying features are superimposed with the base structures, producing abruptly discontinuous variations in the shape of the base structures. Diffraction elements may be formed in one or both of the base structures and the modifying features. The modifying features can be formed by moving the cutting tool in the x-direction, in the z-direction, or along a trajectory having both an x component and a z component.