Methods for making microreplication tools

A method for cutting a pattern in a work piece, wherein the pattern comprises adjacent features separated by a pitch spacing P, the method comprising:

• providing a cutting tool assembly comprising a first tool shank with a first cutting tip to create a first feature in the work piece and a second tool shank with a second cutting tip to create a second feature in the work piece, wherein a distance Y between the first cutting tip and the second cutting tip is equal to nP, and wherein n is an even integer;
• rotating the work piece with respect to the cutting tool assembly;
• beginning at a starting position, advancing the cutting tool along a lateral direction with respect to the rotating work piece, wherein the tool is advanced along the lateral direction a distance of 2Y for each rotation of the work piece;
• returning the cutting tool to the starting position and advancing the cutting tool a distance P along the lateral direction to an offset starting position;
• and
• beginning at the offset starting position, advancing the cutting tool along the lateral direction with respect to the rotating work piece, wherein the cutting tool is advanced a distance of 2Y for each rotation of the work piece.

A method for cutting a pattern in a work piece, wherein the pattern comprises adjacent features separated by a desired pitch spacing P and a maximum acceptable departure Δ from P, the method comprising:

• providing a cutting tool assembly comprising a first tool shank with a first cutting tip to create a first feature in the work piece and a second tool shank with a second cutting tip to create a second feature in the work piece;
• setting a distance a distance Y=nP between the first and second cutting tips, wherein n is an integer greater than ε/Δ, and wherein ε is an accuracy in achieving a desired spacing between the first and second cutting tips;
• measuring an actual distance S between the first and second cutting tips;
• rotating the work piece with respect to the cutting tool assembly;
• and
• advancing the cutting tool along a lateral direction with respect to the rotating work piece, wherein the cutting tool is advanced along the lateral direction a distance of 2P′ for each rotation of the work piece, wherein P′=S/n.