Methods for manufacturing an embosser drum for use in pre-formatting optical tape media

A method, comprising:

• providing a metallic shim that includes a surface having a pattern of nanometer-scale grooves;
• interconnecting opposing end surfaces of the metallic shim together at a single seam to form a cylinder, wherein an interior surface of the cylinder comprises the pattern of nanometer-scale grooves;
• applying a metallic layer to the interior surface of the cylinder to form an embosser drum on the interior surface of the cylinder;
• and
• removing the cylinder from the embosser drum, wherein an outer embossing surface of the embosser drum comprises the pattern of nanometer-scale grooves and is free of welded seams, wherein the removing includes:
• cutting the cylinder along the single seam;
• and
• separating the cylinder from the embosser drum.

A method for use in fabricating an embosser drum, comprising:

• using an embossing master that includes a surface with a pattern of nanostructures to create an embossing plate that includes a pair of opposing end surfaces and a pair of opposing major surfaces, wherein the embossing plate includes the pattern of nanostructures on a first of the opposing major surfaces, and wherein the using includes:
• making a plurality of replicas of the embossing master, wherein each of the replicas includes a surface having the pattern of nanostructures;
• bonding the plurality of embossing master replicas together to create a bonded replica structure including a surface having a pattern of nanostructures thereon, wherein the pattern of nanostructures on the surface of the bonded replica structure comprises the combination of the patterns of nanostructures of the plurality of embossing master replicas;
• producing a replica of the bonded replica structure;
• and generating the embossing plate from the replica of the bonded replica structure;
• forming a cylinder with the embossing plate, wherein an interior surface of the cylinder comprises the first major opposing surface of the embossing plate;
• producing, using the interior surface of the cylinder, an embosser drum, wherein an outer embossing surface of the embosser drum comprises the pattern of nanostructures;
• and separating the cylinder from the embosser drum, wherein the separating includes:
• cutting the cylinder;
• and removing the cylinder from the embosser drum.