Method for reproducing holograms, kinoforms, diffractive optical elements and microstructures

A method of forming a molding tool having a negative microstructure embedded therein, the molding tool for use in molding a plastic element having a positive microstructure corresponding to the negative microstructure, comprising the steps of:

• defining a positive microstructure for performing a predetermined function;
• converting the defined positive microstructure into at least one pattern corresponding to a negative of the defined positive microstructure;
• and
• machining directly into a molding base element a negative microstructure corresponding to said pattern without machining material other than the molding base element.

A method of molding a plastic element having a microstructure embedded therein, comprising the steps of:

• defining a microstructure for performing a predetermined function;
• converting the defined microstructure into at least one pattern corresponding to a negative of the defined microstructure;
• machining directly into a molding base element a negative microstructure corresponding to said pattern without machining material other than the molding base element;
• placing the machine base element into a molding machine;
• introducing a plastic element into the molding machine;
• transferring the negative microstructure from the molding base element into a positive microstructure in the plastic element, the plastic element with microstructure refracting and diffracting light beams passing therethrough;
• and
• removing the molded plastic element having the positive microstructure from the molding machine.

A method of molding a plastic element having a microstructure, comprising the steps of:

• defining a microstructure for performing a predetermined function;
• converting the defined microstructure into at least one pattern corresponding to a negative of the defined microstructure;
• machining directly into a molding base element a negative microstructure corresponding to said pattern without machining material other than the molding base element;
• placing the machined base element into a molding machine;
• introducing a plastic element into the molding machine;
• transferring the negative microstructure from the molding base element into a positive microstructure in the plastic element, the plastic element and microstructure correcting thermal and/or chromatic aberrations in light passing therethrough;
• removing the molded plastic element having the positive microstructure from the molding machine.

A method of molding a plastic element having a microstructure embedded therein, comprising the steps of:

• defining a microstructure for performing a predetermined function;
• creating at least one primitive from the defined microstructure, the primitive corresponding to a negative of the defined microstructure;
• converting the at least one primitive into at least one mask, said mask having at least one opening therein;
• machining the predetermined microstructure into a molding base element directly through the openings in the mask without machining material other than the molding base element;
• placing the machined base element into a molding machine;
• introducing a plastic element into the molding machine;
• transferring the microstructure from the molding base element to the plastic element;
• and
• removing the molded plastic element from the molding machine.