Polymer microwedges and methods of manufacturing same

A method of casting a micro-scale structure in a mold, the method comprising:

• providing a mold including a negative pattern for the micro-scale structure in a first cavity in an upper surface of the mold, and standoff cavities disposed in the first cavity outside of the negative pattern for the micro-scale structure;
• depositing a casting material on the negative pattern;
• and
• curing the casting material.

A method of forming a mold for casting a micro-scale structure, the method comprising:

• adhering a base of a patch including a micro-scale structure on a surface opposite the base to a plate with a roller covered in a compliant material layer;
• depositing mold material on the patch;
• curing the mold material;
• and
• removing the plate and patch from the mold material after the mold material has cured.

A mold for casting a micro-scale structure, the mold comprising:

• a wax body having an upper surface including a first cavity having a first depth, and at least one tapered side wall;
• a first negative pattern for an array of micro-scale elements defined in a surface of the first cavity;
• at least one second cavity having a second depth defined in the first cavity outside of the first negative pattern for the array of micro-scale structures, the at least one second cavity defining a second negative pattern for a standoff of the micro-scale structure;
• a base plate;
• and
• a retainer having a tapered surface corresponding to a taper of the at least one tapered side wall of the wax body and configured to secure the wax body to the base plate.