Thermoplastic forming tools, assemblages thereof, and methods of making and methods of use thereof

A thermoplastic forming assemblage for forming a thermoplastic component having precision micro-scale features and reproducible macro-scale dimensions, the thermoplastic forming assemblage comprising:

• (a) a top tool comprising:
• a first rigid tool body having a first cavity-forming side;
• and
• a first elastomer layer conformally coating at least a portion of the first cavity-forming side to create a first cavity-forming surface;
• and
• (b) a bottom tool comprising:
• a second rigid tool body have a second cavity-forming side and a second elastomer layer conformally coating at least a portion of the second cavity-forming side to create a second cavity-forming surface;
• wherein, when in a closed position, the first cavity-forming surface and the second cavity-forming surface define a cavity for forming the thermoplastic component;
• wherein one or both of the first cavity-forming surface and the second cavity-forming surface comprise a feature-forming surface that define the precision micro-scale features when forming the thermoplastic component;
• wherein the first rigid tool body and the second rigid tool body are effective to provide the reproducible macro-scale dimensions in the thermoplastic component when formed;
• and
• wherein the first elastomer layer and the second elastomer layer are effective to form the precision micro-scale features in the thermoplastic component and to release the precision micro-scale features when formed.