High precision replication system

A method for forming a replica by replicating a smooth replication surface of a substrate comprising the steps of:

• a) applying to the replication surface a graded transition layer, the transition layer comprising a binding material that adheres strongly to the replication surface and a release material that adheres to the replication surface with substantially less force than does the binding material, the transition layer being applied so that the portion of the transition layer closest to the replication surface comprises predominantly the binding material and the portion of the transition layer farthest from the replication surface comprises predominantly the release material, with portions therebetween comprising both materials;
• b) applying to the transition layer a separation layer formed of a material that adheres to the release material with less force than the transition layer adheres to the replication surface;
• c) applying to the separation layer a coating;
• and
• d) separating the coating with the separation layer adhered thereto from the transition layer to yield the replica.

A method for forming a replica by replicating a smooth replication surface of a glass substrate comprising the steps of:

• a) applying to the replication surface a graded transition layer, the transition layer being substantially transparent, having a thickness of less than about 1000 Angstroms, and comprised of a binding material that adheres strongly to the replication surface and a release material that adheres to the replication surface with substantially less force than does the binding material, the transition layer being applied so that the portion of the transition layer closest to the substrate comprises predominantly the binding material and the portion of the transition layer farthest from the substrate comprises predominantly the release material;
• b) applying to the transition layer a substantially transparent separation layer having a thickness of less than about 1500 Angstroms, the transition layer being formed of a material that adheres to the release material with less force than the transition layer adheres to the replication surface;
• c) applying to the separation layer a coating at least 1000 Angstroms thick;
• and
• d) separating the coating with the separation layer adhered thereto from the transition layer to yield the replica, by (i) applying to the coating a substantially void free adhesive, (ii) applying a backing to the coating, with substantially no voids between the adhesive and the backing, and (iii) applying a sufficient separating force to the backing to separate the separation layer from the transition layer.