Abstract: The present invention relates to methods of making microstructured laminae for replication and apparatus. In a preferred embodiment, the invention relates to machining V-shaped grooves on individual lamina forming cube-corner microstructures.

Abstract: In one embodiment, a tool used for creating grooves in a microreplication tool is described. The tool includes a mounting structure and a multi-tipped diamond mounted in the mounting structure. The different tips of the diamond may correspond to different grooves to be created in the microreplication tool. In this manner, the creation of a microreplication tool using a diamond can be simplified and/or improved.

Abstract: In one embodiment, a cutting tool assembly used for creating grooves in a microreplication tool is described. The cutting tool assembly includes a mounting structure and multiple diamonds mounted in the mounting structure. For example, first and second tool shanks having first and second diamond tips can be positioned in the mounting structure such that a cutting location of a diamond cutting tip of the first tool shank is a defined distance from a cutting location of a diamond cutting tip of the second tool shank. The defined distance may correspond to an integer number of pitch spacings, and may be accurate to within a tolerance of less than approximately 10 microns.

Abstract: A carrier tape includes a longitudinal strip having a plurality of component receiving pockets positioned therein. The pocket depth is greater than a thickness of the longitudinal strip. Adjacent pockets are spaced apart by a distance less than approximately five times the thickness of the longitudinal strip. Sidewalls separating adjacent pockets have a height greater than the pocket depth minus a height of a component which the pockets are configured to receive. The carrier tape is produced by providing a rotatable tool and a nip roll having a conformable outer circumferential surface opposed to the tool. The outer circumferential surface of the tool includes projections for forming the pockets. A polymer web is introduced into a nip between the tool and the nip roll, and embossed with the projections on the circumferential surface of the tool.