Abstract: In a method for manufacturing an optical fiber probe in which an optical fiber is formed as an optical fiber probe by etching a tip section and sharpening a core region of the optical fiber, the optical fiber is a polarization maintaining optical fiber including the core region, a stress-applying region, and a clad region. The optical fiber probe is formed by mechanical-grinding of the edge of the optical fiber into a sharpened shape so that the core region is located at the tip of a sharpened portion, and by dipping the formed edge of the optical fiber in an etchant for further sharpening the core region. Accordingly, a new optical fiber probe both with high transmission efficiency and with a large polarization degree is obtained.

Abstract: A security article includes a light transmissive substrate having a first surface and an opposing second surface, with the first surface having an embossed region with an optical diffraction pattern or a holographic image pattern. A color shifting optical coating is formed on the substrate such as on the opposing second surface, with the optical coating providing an observable color shift as the angle of incident light or viewing angle changes. The security article can be used in a variety of applications and products to provide for enhanced security measures such as anticounterfeiting.

Abstract: A rolled optical film includes a cellulose ester film which has a width of from 1 m to 3 m and a length of 500 m or more and is shaped in a rolled film. The cellulose ester film includes streaks from 1 line to 20 lines per 10 mm in a lateral direction thereof in which the streaks have a height of from 50 nm to 300 nm, an inclination of from 50 nm/mm to 300 nm/mm and a continuous length of 50 cm or more in a longitudinal direction thereof and the cellulose ester film does no includes a streak which has a height of 300 nm or more, an inclination of 300 nm/mm or more and a continuous length of 50 cm or more in a longitudinal direction thereof.

Abstract: A method of producing an optical film comprising the step of: stretching a continuous resinous film by apply tension to a transverse direction of the resinous film while conveying the resinous film, wherein the stretching is carried out with a stretching apparatus comprising right and left edge holding devices which hold right and left edges of the resinous film; and, the right and left edge holding devices of the stretching apparatus each independently controls right and left edge holding distances of the resinous film so that a slow axis of the resinous film is substantially perpendicular or substantially parallel to a film conveying direction, provided that the edge holding distance is defined as a distance between an initiation position and a cessation position of holding of the edge of the resinous film.

Abstract: Disclosed is a process for producing a layered article including a substrate and an inorganic particle layer formed thereon, the process including: preparing a mixed inorganic particle dispersion comprising a liquid dispersion medium containing inorganic particles (A) and inorganic particles (B), the mixed inorganic particle dispersion being characterized by conditions (1) regarding particle size, (2) regarding volume fraction of inorganic particles and (3) regarding weight fraction; applying the mixed inorganic particle dispersion to a substrate, and removing the liquid dispersion medium from the mixed inorganic particle dispersion applied to form an inorganic particle layer on the substrate.

Abstract: An optical film comprising a cycloolefin resin or a cellulose ester resin, wherein (a) at least one of edges of the optical film is slit; (b) an average surface roughness Ra specified in JISB0601-2001 of a cross-section of the optical film formed by slitting is 0.05 to 0.9 ?m; and (c) a width of the optical film is 1400 mm or more.

Abstract: Illumination lenses (1806, 1902, 2002, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 3006, 3100) having surfaces shaped according to given differential equations in order to distribute light in a highly controlled manner with minimum reflection losses are provided. Both primary lenses and secondary lenses are provided. The secondary lenses include outer surfaces that are defined as loci of constant optical distance from an origin at which a light source is located. Versions are provided of both the primary and secondary lenses having Total Internal Reflection (TIR) wings. These are useful in the case that narrower distributions of light are required. A method of refining the shape of the lenses to obtain more obtain lenses that produce better fidelity ideal light distributions is also provided.

Abstract: An optical lens manufacturing method according to the present invention comprises: an optical lens base material preparation step of preparing an optical lens base material 40, which is formed of light transmitting material, has a columnar shape, and is provided with a first side face 44 and a second side face 46 that are mutually parallel, of which at least one of both first side face 44 and second side face 46 has a plurality of curved surface parts 43; a drawing step of drawing optical lens base material 40 in the columnar axis direction; and an optical lens preparation step of cutting optical lens base material 40, which has been drawn, at a desired length to thereby prepare optical lens 1. The plurality of curved surface parts 43 of optical lens base material 40, which has been drawn in the drawing step, function as optical action components that act on incident light or emitted light.

Abstract: The present invention provides a method and a formulation for consistently producing a silicone hydrogel material having relatively high oxygen permeability, relatively high ion permeability, and low modulus, and contact lenses prepared from a formulation of the invention or made of a silicone hydrogel material of the invention.

Abstract: A method of testing a convex mirror surface figure in which an optical quality substrate material is used having a convex front surface and a rear surface polished to a precise optical figure to create a lens. The lens is then tested by a standard interferometric or wavefront lens-testing method and the convex surface coated once a desired curvature is obtained. Null testing may be attained by passing a collimated interferometer beam through a focusing lens shaped to counter the predicted spherical aberration introduced by a perfect convex mirror/lens. A nominal rear surface figure of the mirror/lens may be used if a precisely figured test window is contacted with the rear surface using a refractive index-matching substance with an index of refraction closely matching the index of refraction of the test optic.

Abstract: A method for producing a mold for a zonal optical element including forming a circular portion where, while rotating a work around a rotation axis corresponding to the optical axis as a center, a tip is relatively moved relative to the work to form the circular portion at the mold side corresponding to the circular portion on the processing surface of the work perpendicular to the rotation axis; forming a zonal surface where the tip is relatively moved relative to the work to form a zonal surface at the mold side corresponding to the zonal surface; and forming a corner portion between the boundary portion at the mold side and the zonal surface at the mold side wherein a raked surface of the tip is in contact with a portion corresponding to the boundary wall surface.

Abstract: Provided is an imprint method that includes the steps of softening resist in an object to be processed, by using compressed gas or supercritical fluid, the object including a substrate and the resist applied onto the substrate, and transferring a predetermined pattern onto the resist by pressing a mold that forms the predetermined pattern against the resist in the object.

Abstract: A color filter substrate for multi-view displaying including a substrate, a light shielding-layer, and a color filter layer is provided. The substrate has a first surface, a second surface, and a plurality of concaves. The first surface is opposite to the second surface. The concaves are located at the first surface. The light-shielding layer disposed on the first surface of the substrate defines a plurality of light-transparent openings. The color filter layer has a plurality of sub-pixel areas including at least one first sub-pixel area and at least one second sub-pixel area. A first light is transmitted to a first viewer by passing through one of the light-transparent openings and one of the at least one first sub-pixel area, and simultaneously, a second light is transmitted to a second viewer by passing through the same one of the light-transparent openings and one of the at least one second sub-pixel area.

Abstract: A method of molding an optical component which includes providing a first mold and a second mold which mold the optical component, a cylindrical body whose rotational symmetry axis is identical with a second symmetry axis about which a second mold is rotationally symmetric, a trunk mold whose rotational symmetry axis is identical with a first symmetry axis about which a first mold is rotationally symmetric, a supporting means which supports the first mold in such a way that the first mold moves relatively to the trunk mold in parallel with the first symmetry axis, and a second tapered surface and a first tapered surface which contacts the second tapered surface, which connect the cylindrical body with the trunk mold in such a way that the second symmetry axis is identical with the first symmetry axis.

Abstract: A method for producing an optical recording medium, includes: filling a plurality of spaces with a liquid photosensitive material, wherein each of the plurality of spaces is surrounded by a surface of a sheet material and partition walls that are formed on the surface of the sheet material for separating a plurality of recording areas, and the surface of the sheet material has recessed parts at positions where the plurality of recording areas is to be formed, each of the recessed parts protruding and deformed to a back surface side of the sheet material so as to have a volume in relation to a volumetric shrinkage factor of the photosensitive material; and pressing a member having a substantially flat surface to a back surface of the sheet material to make the recessed parts substantially flat and heating and hardening the photosensitive material to form the plurality of recording areas.

Abstract: A method of making an optical film includes the steps of making a substrate having a first major surface and a second major surface opposite the first surface and forming a plurality of curved sided cone structures on the first surface. Each of the curved sided cone structures include a base located on the first surface, a vertex, and a curved side formed from an arc extending between the base and the vertex. The optical gain and viewing angle for the film can be controlled by adjusting angles representing a shape of each curved sided cone structure at its vertex and base.

Abstract: A plastic lens molding method includes: preparing a lens preform having the temperature equal to or higher than a glass transition point temperature; and molding a lens by compressing the lens preform having the temperature equal to or higher than the glass transition point temperature, the compressing of the lens preform being performed by a mold providing a finished lens dimension at a constant temperature equal to or lower than the glass transition point temperature.

Abstract: An optical element is manufactured using a replication tool comprising a negative structural feature defined in a replication side of the replication tool, and a peripheral feature formed in the replication side of the replication tool adjacent the negative structural feature. The negative structural feature defines the shape of the optical element. A replication material is disposed between a substrate and the replication tool, which are moved toward each other. The peripheral feature confines the replication material to a predetermined area of the substrate. The replication material can be hardened to form the optical element from the replication material attached to the substrate.

Abstract: Embodiments of the present invention provide an intraocular lens with an optic zone having a first surface topology and a haptic zone having a second surface topology. The surface roughness of the haptic zone may be greater than the surface roughness of the optic zone. The surface topology of the optic zone may have a first surface geometry and the surface topology of the haptic zone may have a second surface geometry. The first and second surface geometries may retain lubrication fluid in a space formed therein. The haptics formed by the manufacturing process may have a reduced ability to adhere to the optic zone, such as when the lens is folded or advanced through a cannula.

Abstract: Method of making eyeglass lens are disclosed where the lens are made of layers which include an outer, convex hard coating, a layer of hard epoxy, a layer of polyurethane mixture film, a PVA film wherein the color is dipped in water with Photochromic powder, a layer of soft epoxy, a base material, and an inner, concave hard coating. Other methods configuration of lens also include an outer, convex hard coating, a layer of hard epoxy, a layer of polyurethane mixture film, a PVA film wherein the color is dipped in water without color dye, a layer of soft epoxy, a base material, and an inner, concave hard coating.

Abstract: An information signal area on an information signal recording surface is provided as pits on a mirror in accordance with modulated information data, and is covered with a metal alloy reflective film. Sections that do not include pits corresponding to the information data are provided in the information signal area, and portions of the metal alloy reflective film on the sections are formed as perforated marks corresponding to the information data. In this case, the reproduction signal amplification level of a prepit signal and the reproduction signal amplitude level of a perforated mark signal can be obtained as substantially equal values by adjusting the depth and width of pits and/or adjusting the width and length of perforated marks. Hence, waveform distortion due to a waveform equalization circuit and variations in binary signals due to displacement of the slice level are reduced so that signals can be stably and reliably detected with the same reading apparatus.

Abstract: Disclosed is an optical element for use in an optical apparatus having a light source which emits a light flux with a wavelength ? (350 nm???450 nm), the optical element containing: a molded portion formed by molding a resin; and one or a plurality of anti-reflection layers formed on the molded portion, wherein at least one of the anti-reflection layers is made of SixOy; and an elemental ratio r (r=y/x) designating an ratio of O to Si in the molecule of SixOy satisfies a requirement represented by Formula (1): 1.40?r?1.80.

Abstract: A method of forming a diffraction grating according to the present invention includes a step of preparing a mold having projections and recesses for forming a diffraction grating, a step of bringing the projections and recesses of the mold into contact with a resin layer in a chamber at a first pressure less than atmospheric pressure, a step of setting a pressure in the chamber to a second pressure more than the first pressure while maintaining the contact, and a step of hardening the resin layer while maintaining the contact between the resin layer and the projections and recesses so as to form a pattern for the diffraction grating on the hardened resin layer. The recesses in the projections and recesses of the mold form a closed pattern in the plane of the mold including the projections and recesses.

Abstract: This invention discloses methods and apparatus for providing an ophthalmic lens with an energy source incorporated therein.

Abstract: The present invention provides a manufacturing method for a wafer lens module including the steps of providing a plastic material with high thermal resistance, wherein the high temperature plastic material can be used at a reflow temperature above 250° C.; and forming the high temperature plastic material into a wafer lens module integrally. The method can form an integrated wafer lens module and simplify the manufacturing procedures. Furthermore, a wafer lens unit formed by stacking another wafer lens module on the wafer lens module manufactured by the method can have improved optical image quality.

Abstract: An optical film manufacturing method, comprising steps of: forming a film by casting a liquid-state resin; embossing both ends of the formed film in a lateral direction of the film so as to form embossed sections for conveying the film; conveying the film having the embossed sections by a freely rotatable conveyance roller; trimming and removing the embossed sections of the film after the conveying step; and winding up the film.

Abstract: There is provided a method of manufacturing a window having at least one of a radio wave stealth property and an electromagnetic wave shield property comprising: a step for forming a thin-film composed of a conductive material on the surface of a transparent window member having a curved surface, and a step for forming the thin-film into a mesh shape. As a result, it is, possible to manufacture, at lower cost, a window having a radio wave stealth property that scatters radio waves in various directions so as not to be detected by radar, while transparency to visible light is improved, as well as a window having an electromagnetic wave shield property that effectively prevents harmful electromagnetic waves, except for visible radiation, from invasion into an aircraft.

Abstract: To provide a production process capable of making the transmittance of an optical glass element obtainable by press-molding a TeO2-containing glass high. A process for producing an optical glass element, which comprises press-molding a TeO2-containing glass, wherein the press-molding is carried out in an atmosphere in which the nitrogen partial pressure is at most 102 Pa. The above process for producing an optical glass element, wherein the face of a mold for the press-molding to be in contact with the glass is made of carbon. The above process for producing an optical glass element, wherein the molded glass obtained by the press-molding is held in an oxygen-containing atmosphere at a temperature within a range of at least a temperature lower by 50° C. than the glass transition point of the TeO2-containing glass and at most the softening point of the glass.

Abstract: A tunable optical cavity can be tuned by relative movement between two reflection surfaces, such as by deforming elastomer spacers connected between mirrors or other light-reflective components that include the reflection surfaces. The optical cavity structure includes an analyte region in its light-transmissive region, and presence of analyte in the analyte region affects output light when the optical cavity is tuned to a set of positions. Electrodes that cause deformation of the spacers can also be used to capacitively sense the distance between them. Control circuitry that provides tuning signals can cause continuous movement across a range of positions, allowing continuous photosensing of analyte-affected output light by a detector.

Abstract: A method for laminating a functional film on to a plastic injection molded lens. An outer layer of the film is selected to perform an HMA-type function when subjected to the heat and pressure of the mold. After forming the lens, the mold is open and the film is loaded in to the empty insert. The residual heat and pressure bonds the film via the HMA to the lens, in a press lamination process. A functionally enhanced lens having a film intimately laminated on to one side.

Abstract: The lens array 1 includes at least one lens part 3 formed on a surface of a glass substrate 2, and is formed of a press-molded article of optical glass having a refractive index nd of not less than 1.75. The method for producing the lens array 1 includes press molding a preform of optical glass having a refractive index nd of not less than 1.75 using a mold having at least one recess for forming the at least one lens part 3.

Abstract: The invention relates to an electrolyte material for an electrically-controllable device having variable optical/energy properties, characterized in that it comprises a self-supporting polymer matrix containing ionic fillers and a liquid for solubilizing said ionic fillers, said liquid not solubilizing said self-supporting polymer matrix, the latter being selected so as to provide a percolation path for said ionic fillers; to an electrically-controllable device having variable optical/energy properties, comprising such an electrolyte material; and to a method for fabricating such an electrically-controllable device, characterized in that the various layers thereof are assembled by calendering or lamination, optionally with heating.

Abstract: In a molding apparatus in which upper and lower dies are held in a bearing, there are provided pipes for introducing N2 gas used for controlling temperatures of balls of the bearing, whereby difference in temperature between the guide member and the upper and lower dies is controlled. With this structure, it is possible to prevent generation of an excessive compressive force between the upper die and the lower die and the bearing, to thereby prevent breakage of the dies. Further, it is also possible to prevent formation of gaps between the upper die and the lower die and the bearing, to thereby mold an optical element excellent in accuracy of an optical axis.

Abstract: A polarizer of the invention comprises a polyvinyl alcohol-based film which is at least dyed with at least iodine and uniaxially stretched, having a single transmittance of 43% or more, a polarizing efficiency of 99.9% or more, and a dichroic ratio of 30 or more, wherein the dichroic ratio is calculated from a parallel transmittance (Tp) and a crossed transmittance (Tc) at a wavelength of 440 nm, and have good hue.

Abstract: A rectangular optical glass lens and a manufacturing method thereof are disclosed. A rectangular glass blank is put between an upper mold and a lower mold of a multi-cavity mold and then being heated and pressured. The rectangular glass blank is molded into a lens sheet having a plurality of optical surfaces and the lens sheet is cut to form a plurality of rectangular optical glass lenses. The rectangular optical glass lens produced by such method includes two optical surfaces working as optical areas and a rectangle circumference on non-optical area surrounding the optical surface. The circumference is a rectangular part with four right angles on each corner while the right angles as well as the rectangular shape are formed by cutting of the lens sheet. Thus the manufacturing method of rectangular optical glass lenses are simplified and the produced lens is assembled with a lens module conveniently.

Abstract: Disclosed is a diffuse reflector comprising a consolidated nonwoven sheet having a thickness standard deviation of about 15 ?m or less and a photopic reflectance of at least about 94% over the wavelength range of 380 nm to 780 nm. Further disclosed is a diffuse reflective article and optical display utilizing such a diffuse reflector, a method for producing such a diffuse reflector, and a method of improving light reflectivity utilizing such a diffuse reflector.

Abstract: The manufacturing efficiency of a light emitter (product) having a lens member and a light emitting device is efficiently improved. With a molding die for forming a light emitter, a frame before the molding and bonding process, with a required number of light-emitting devices mounted thereon, is set on a setting section provided in an upper die. A required amount of transparent liquid resin material is supplied by a dispenser into each of cavities of cavity blocks provided in a lower die in correspondence to the light-emitting devices, respectively. A molding die is closed so as to elastically press the mouths of the cavities onto the light emission surfaces of the light emitting devices, respectively.

Abstract: Disclosed is an optical film having good haze properties, wherein bleedout hardly occurs and deformation problems of the raw material film such as horseback defects and projection defects do not occur even when the film is stored for a long time. Also disclosed are a method for producing such an optical film, a polarizing plate using the optical film, and a liquid crystal display using the polarizing plate. Specifically disclosed is an optical film characterized by containing at least one polymer compound derived from a compound represented by the following general formula (1). [chemical formula 1] (1) (In the formula, R1-R6 independently represent a hydrogen atom or a substituent, and R1 and R2 may combine together to form a substituent bound by a double bond. In this connection, at least one of R1-R6 represents a group having a polymerizable group as a partial structure.

Abstract: An electrically controllable/electrochemical device, having variable optical and/or energy properties, including at least one carrier substrate including a first electronically conductive layer, a first electrochemically active layer capable of reversibly inserting ions such as cations, H+, or Li+, or anions, OH?, or anions made of an anodic (or respectively cathodic) electrochromic material, an electrolyte layer, a second electrochemically active layer capable of reversibly inserting the ions, or made of a cathodic (or respectively anodic) electrochromic material, and a second electronically conductive layer. At least one of the electrochemically active layers capable of reversibly inserting the ions, or made of an anodic or cathodic electrochromic material, has a sufficient thickness to allow all the ions to be inserted without electrochemically disfunctioning the active layers.

Abstract: Methods of forming a lens master wafer having aspheric lens shapes. In one embodiment, a substrate is coated with a polymer material. Isolated sections are formed in the polymer material. The isolated sections are reflowed. The reflowed sections are formed into aspheric lens shapes using a lens stamp.

Abstract: A method of shaping an aspherical optical element, such as a composite mirror element, the method comprising the following steps: fastening, preferably by adhesive, an optical element blank, presenting an optical surface that is to be shaped, to the inside of a ring, the optical surface of the blank projecting beyond an edge of said ring; applying forces and moments to the perimeter of the ring in such a manner as to deform it in controlled manner, thereby also deforming the optical surface of the blank fastened to its inside; shaping said deformed optical surface by abrasion so as to restore it to a shape that is spherical or planar; and extracting the blank from the ring so as to release the stresses deforming said shaped optical surface, thereby enabling it to acquire the desired aspherical shape.

Abstract: An anti-glare film is provided and includes micro concave/convex portions on a surface. An average interval between the micro concave and convex portions is equal to 300 ?m or less. A differentiation with respect to angle d{Log(I(?))}/d? of a logarithm intensity of reflection Log(I(?)) in a direction of a deviation angle ? from a direction of specular reflection has an extreme value. A differentiation d{Log(P(?)}/d? of a histogram P(?) to an inclination angle ? of the micro concave/convex portions has an extreme value. In the anti-glare film 1, a value C(2.0) of transmitted image clarity measured by using an optical comb of a comb width of 2 mm in accordance with JIS-K7105 is equal to 30% or more, and a ratio C(0.125)/C(2.0) of the value C(2.0) measured by using the optical comb of the comb width of 2 mm and a value C(0.125) measured by using an optical comb having a comb width of 0.125 mm is equal to 0.1 or more.

Abstract: An intraocular lens includes an optic adapted to focus light toward a retina of an eye, and at least one fixation member configured to at least assist in supporting the optic in the eye. The fixation member includes a proximal portion coupled to the optic and a distal portion configured to be in contact with eye tissue when the intraocular lens is in use in the eye. The proximal portion of the fixation member includes at least one first area formed of a first, substantially rigid material, and at least one second area formed of a second material which is more flexible than the first material.

Abstract: The invention provides a continuous method for producing polarizing films that includes a step of monoaxially stretching a polyvinyl alcohol film having a width of at least 2 m in an aqueous boric acid solution, wherein the polyvinyl alcohol film is stretched on the condition that it satisfies the following formulae (1) and (2): A?5 (m)??(1) A/B?0.5 (min) (2) wherein A indicates the stretching distance (m); and B indicates the stretched film speed (m/min). The method gives wide polarizing films of wide and good polarization performance, and the polarizing films thus produced are useful as the material for polarizers that may be in large-size liquid-crystal displays.

Abstract: The inventive method for recording data on an optical lens (2) consists in recording a data-containing source image, in generating the hologram (3) of the image source and in recording said hologram on the lens surface portion ranging from 0.5 mm2 to 15 mm2. The data can be read-out by illuminating said lens by means of a light beam (101) in the hologram area. A read-out image (105, 106) which reproduces the source image and on which data is readable is formed at a distance from the lens. Said lens can be embodied, in particular in the form of an ophthalmic lens.

Abstract: Disclosed is a method for manufacturing an optical component in three dimensions. In one aspect, the method includes providing a substrate that includes contiguous rigid plates that are disposed such that a major surface of each rigid plate lies substantially in a single plane. At least one of said surfaces is characterized by a micro-optical structure. Further in the method, the substrate is folded such that the at least one surface having a micro-optical structure and at least one other of the above-recited surfaces are disposed at an angle to one another. A second method is also disclosed. Disclosed structures made by the method(s) include a mesa structure with a top plate and four sidewall plates, each facing a reflective plate, as well as closed structures such as cubes and rectilinear boxes into which separate plates may be disposed. A mold for preferentially making the substrate such as by injection molding is also detailed.

Abstract: A laser beam output from a semiconductor laser light source 1 is transmitted through a cover glass 2 in the optical axis Z direction, is incident on a molded lens 4 in a state of divergent rays, is converted into convergent rays by the molded lens 4, and is applied onto a recording face 5 of the optical recording medium. A diaphragm 3 is arranged. An area of each lens surface onto which a luminous flux of the laser beam restricted by the diaphragm 3 is applied corresponds to an effective area. The following expression (1) is satisfied: d1?d0?0.04 mm??(1) where d0 denotes an effective aperture of one of the lens surfaces, and d1 denotes an outer diameter of the one of the lens surfaces.

Abstract: An optical member includes a base body, a plurality of light-concentrating lenses and a plurality of light-diffusing patterns. The base body has a first surface and a second surface which is opposite to the first surface and receives light from light sources. The light-concentrating lenses are formed on the first surface. The light-diffusing patterns are respectively formed at positions of the second surface respectively corresponding to the light sources to reduce an amount of light reflected by the light-concentrating lenses. Each of the light-diffusing patterns includes curved surfaces extending in a first direction and has a width which is in a predetermined range. The light-diffusing patterns are separated from one another in a second direction substantially perpendicular to the first direction.

Abstract: Light-diffracting microstructures are produced by the superimposition of at least two relief structures, wherein the first relief structure is produced mechanically while at least one second relief structure is a photomechanically generated diffraction structure.

Abstract: A method of molding provides two molds (102, 104) formed of semiconductor material. The molds (102, 104) have substantially planar working faces (108, 110) into which recesses (106, 112) are formed. In use the molds (102, 104) are pressed together with the working faces (108, 110) opposed so the recesses (106, 112) form mold cavities. The molds (102, 104) only contact each other in the plane of the working faces (108, 110). A thermoplastic sheet placed between the molds is heated to deform the sheet into the mold cavities.