Methods for manufacturing display device lenses

A method of making a lens shaping roller, the method comprising:

• forming a patterned planar surface into a cylinder, a first set of one or more patterns in an interior portion of the cylinder;
• inserting a die mold in the interior portion of the cylinder over the first set of one or more patterns to form a second set of one or more patterns;
• and
• separating the die mold from the cylinder to expose the second set of one or more patterns in an outer portion of the die mold.

A method for making a shape forming roller used in manufacturing projection television screens, the method comprising:

• patterning a flat plate die into a silicone rubber mold die;
• forming the patterned silicone rubber mold die into a cylindrical die using a reinforcing tube;
• fabricating a metal die at an interior portion of the cylindrical die;
• removing the silicone rubber mold die and the reinforcing tube;
• and
• manufacturing a forming roll by inserting and fixing a shaft into the metal die.