Methods and apparatus for forming variable spaced relief patterns with a single tool pair and articles produced thereby

A method for making an embossed article where the article comprises a first composite design element having a plurality of spaced apart design subelements, the method comprising:

• mounting a first embossing tool to an embossing press wherein the first embossing tool includes first and second male dies, each die comprising embossing means for creating at least one design subelement, and a space there between;
• mounting a second embossing tool to the embossing press in registered opposition to the first embossing tool wherein the second embossing tool includes first and second female dies complementary in number, type and position to the respective first and second male dies, and a space there between;
• positioning a first deformable sheet material between the first and second embossing tools, and operating the tools with sufficient force to cause deformation of the first sheet material;
• modifying the inter-die spacing between the first and second dies in the first and second embossing tools, and
• positioning one of a) the first deformable sheet material or b) a second deformable sheet material between the modified first or second embossing tools, and operating the tools with sufficient force to cause deformation of the first or second sheet material.