Ultra-flexible retroreflective cube corner composite sheetings and methods of manufacture

A method of manufacturing microstructured composite sheeting comprising the steps of:

• a) providing a tool having a molding surface with a plurality of cavities opening thereon suitable for forming desired microstructures;
• b) applying to said molding surface a volume of a flowable curable resin composition suitable for forming desired microstructure elements;
• c) contacting said resin composition with a first major surface of a transparent overlay film having first and second major surfaces;
• and
• d) minimizing excess resin composition extending above said cavitites and tool;
• then e) curing said resin composition while in contact with said overlay film to form a sheeting comprising an array of microstructure elements bonded to said overlay film;
• then
• f) removing said sheeting from said tool;
• and
• g) applying mechanical stress to said sheeting so as to cause a fractured separation of substantially each individual microstructure element from surrounding microstructure elements;
• wherein said resin composition and said overlay film are such that said resin composition penetrates said overlay film when contacted thereto such that after said curing said array of cube corner elements are bonded to said overlay film through as interpenetrating network between the material of said microstructure elements and the material of said overlay film.