Method for precise molding and alignment of structures on a substrate using a stretchable mold

A process for forming and aligning microstructures on a patterned substrate comprising the steps of:

• placing a mixture comprising a curable material between the patterned substrate and a patterned surface of a mold, the patterned surface of the mold having a plurality of micro structures thereon;
• heating the mold to align a portion of the patterned surface of the mold with at least a portion of the patterned substrate;
• curing the curable material to a rigid state adhered to the substrate;
• and
• removing the mold to leave hardened structures of the mixture aligned with the pattern of the substrate, the hardened structures substantially replicating the microstructures of the patterned surface of the mold.

A process for forming and aligning microstructures on a patterned substrate comprising the steps of:

• coating a mixture comprising a curable material onto the patterned substrate;
• bringing a patterned surface of a mold into contact with the curable material coated onto the substrate, the patterned surface of the mold having a plurality of microstructures thereon;
• stretching the mold to align a portion of the patterned surface of the mold with at least a portion of the patterned substrate;
• curing the curable material to a rigid state adhered to the substrate;
• and
• removing the mold to leave hardened structures of the mixture aligned with the pattern of the substrate, the hardened structures substantially replicating the microstructures of the patterned surface of the mold.

A process for forming and aligning micro structures on a patterned substrate comprising the steps of:

• placing a mixture comprising a curable material between the patterned substrate and a patterned surface of a mold, the patterned surface of the mold having a plurality of microstructures thereon;
• stretching the mold to align a portion of the patterned surface of the mold with at least a portion of the patterned substrate;
• curing the curable material to a rigid state adhered to the substrate;
• and
• removing the mold to leave hardened structures of the mixture aligned with the pattern of the substrate, the hardened structures comprising a substantial replica of the microstructures of the patterned surface of the mold and a land portion disposed between the patterned substrate and the substantial replica of the microstructures of the patterned surface of the mold.