Method of replicating a high resolution three-dimensional imprint pattern on a compliant media of arbitrary size

A method of replicating a high resolution three-dimensional imprint pattern on a compliant media, comprising:

• forming an imprint stamp on a master substrate by patterning and then etching the master substrate to define an imprint pattern in the substrate;
• depositing a release layer over the imprint pattern, the release layer including a first thickness operative to conformally coat the imprint pattern;
• depositing a silicone-based elastomer layer over the release layer to a first depth operative to completely cover the imprint pattern;
• curing the silicone-based elastomer layer by heating the master substrate;
• releasing the silicone-based elastomer layer from the release layer;
• separating the imprint stamp from an excess portion of the silicone-based elastomer layer that surrounds the imprint stamp;
• repeating the above steps, as necessary, to form additional imprint stamps from the master substrate;
• placing a flat and thin plastic film having a third thickness on a flat and compliant silicone rubber backing having a fourth thickness;
• coating a surface of the thin plastic film with a photopolymer solution;
• spreading the photopolymer solution over the surface of the plastic film to form a photopolymer layer having a fifth thickness;
• placing a patterned surface of the imprint stamp on the photopolymer layer;
• curing the photopolymer layer to fix a position of the imprint stamp on the photopolymer layer and to transfer an image of the imprint pattern on the patterned surface of the imprint stamp to the photopolymer layer by irradiating the photopolymer layer with an ultraviolet light of a predetermined intensity for a first time period;
• separating the imprint stamp from the photopolymer layer so that the image of the imprint pattern defines a photopolymer shim;
• post-curing the photopolymer shim by heating the photopolymer shim;
• depositing a coating of a fluorocarbon material having a sixth thickness on the photopolymer shim;
• separating the thin plastic film from the silicone rubber backing;
• attaching the photopolymer shim to a support substrate;
• attaching a shim stock having a first height to the support substrate, the shim stock is positioned adjacent to the photopolymer shim and is spaced apart from the photopolymer shim by a first distance;
• coating the photopolymer shim and the shim stock with a compliant material selected from the group consisting of a silicone-based elastomer material and an amorphous fluoropolymer material;
• spreading the compliant material over the photopolymer shim and the shim stock to form a compliant media that covers the photopolymer shim and the shim stock and to transfer the imprint pattern in the photopolymer shim to the compliant media;
• heating the support substrate;
• cooling the support substrate;
• separating the shim stock from the compliant media;
• applying a first adhesive surface of a transfer adhesive layer to a surface of the compliant media so that the transfer adhesive layer adheres to the compliant media, the transfer adhesive layer includes a seventh thickness and a second adhesive surface;
• and
• separating the compliant media from a selected one of the support substrate or the photopolymer shim by peeling back the transfer adhesive layer.