Light modulator having bonded structures embedded in viewing area and methods of making light modulators

A method of making a switchable light modulator comprising:

• providing a first substrate including a first major surface,
• coupling a polymer film to the first major surface;
• embossing the polymer film to create a plurality of cavities, wherein the embossing process creates a polymer wall structure surrounding each cavity, the polymer wall structure having a top and a bottom wherein the top of the polymer wall structure includes a mould part defining a recess along the top of the polymer wall structure, and
• wherein the embossing process also creates a peripheral edge seal including the polymer wall structure having the mould part;
• providing a modulating fluid in discrete volumes within the plurality of cavities and adjacent the peripheral edge seal;
• depositing a fluid pre-cursor in the recess of the polymer wall structure;
• disposing a second substrate having a second major surface atop the polymer wall structure of the cavities and the peripheral edge seal such that the second major surface contacts the fluid pre-cursor;
• and
• curing the fluid pre-cursor, thereby sealing the cavities and the peripheral edge seal to the second major surface.