A method for forming a retroreflective prism in a substrate includes inserting and retracting a single point diamond tool through a surface of the substrate while moving the single point diamond tool, the substrate, or both the single point diamond tool and the substrate in a direction of travel along at least one axis to generate a facet in the substrate having a facet face parallel to the direction of travel of at least one of the single diamond point tool or the substrate. The facet face has an angle defined by a chiseling edge of the single point diamond tool. The inserting and retracting is repeated at a plurality of locations on the substrate to form an array of retroreflective microstructures on the surface of the substrate. At least one of the array of retroreflective microstructures is a retroreflective prism having a polygonal projected aperture.

A retroreflector element is divided into multiple reflection regions. The triples of a first reflection region are designed for the purpose of reflecting incident light beams parallel to the preferred direction, at a narrow angle distribution. The side surfaces of the triples of the first reflection region preferably stand precisely perpendicular on one another. The second reflection region is designed to reflect another part of the incident light falling onto the retroreflection element, independent of the preferred direction, at an observation angle between 0 and 2. The second reflection region ensures that the retroreflection element remains visible at an observation angle up to at least 2, even perpendicular to the preferred direction.

A retroreflector includes a regular arrangement of multiple reflective triples of the first type, each having three side surfaces of the first type, which triples stand approximately perpendicular to one another, in pairs, and define a cube corner having an apex, at which the planes spanned by the three side surfaces of the first type intersect. A number of selected triples of the first type each have a recess, in particular a cube-shaped recess in the surface of the related cube corner and/or an elevation, in particular a cube-shaped elevation projecting from the surface of the related cube corner, which forms a triple of the second type, wherein the triples of the second type each have at least three side surfaces of the second type, which stand approximately perpendicular to one another, in pairs.

A method of manufacturing a primary mold for the forming of a retroreflective screen, the method including the steps of: a) forming, on the front surface of such a substrate, a layer of a material such that the first substrate is selectively etchable over said layer; and b) forming microrecesses from the rear surface of the first substrate by selective etching of the first substrate over said layer, each microrecess emerging on the rear surface of said layer and having a back parallel to the front surface of the first substrate and first and second lateral walls orthogonal to each other and orthogonal to the back the first and second lateral walls and the back of the microrecess joining at a same point and forming a trihedron.

A retroreflector includes a regular arrangement of multiple reflective triples of the first type, each having three side surfaces of the first type, which triples stand approximately perpendicular to one another, in pairs, and define a cube corner having an apex, at which the planes spanned by the three side surfaces of the first type intersect. A number of selected triples of the first type each have a recess, in particular a cube-shaped recess in the surface of the related cube corner and/or an elevation, in particular a cube-shaped elevation projecting from the surface of the related cube corner, which forms a triple of the second type, wherein the triples of the second type each have at least three side surfaces of the second type, which stand approximately perpendicular to one another, in pairs.

Methods of making tiled articles and molds used to make retroreflective articles. The methods include forming a prism array on a master substrate and forming a replica of the master. A reference edge is formed on the replica, thereby reducing the size of the prism array, yet maintaining a lateral dimension of the replica to maintain ease of handling of the replica. The replica is copied and the reference edge on the copied tiles are exposed, such that the reference edge can be mated and secured face-to-face with a reference edge on other tiles in order to form a tiled article. The tiled article is used as a mold to produce retroreflective articles or can be further duplicated and mated to form larger tiled articles to be used as molds. Tiled articles used as molds and retroreflective articles produced from the molds are also disclosed.

A retroreflector includes an arrangement of triples, each having three side surfaces, which are disposed in the manner of a cube corner and stand approximately perpendicular on one another. The retroreflector can be produced from a carrier material by injection molding. An optical silicone resin is used as the carrier material. The retroreflector is based on triple mirrors that are both easily unmolded from a die and easily applied to curved surfaces even after unmolding or are usable for reflection of ultraviolet light.

A retroreflector element is divided into multiple reflection regions. The triples of a first reflection region are designed for the purpose of reflecting incident light beams parallel to the preferred direction, at a narrow angle distribution. The side surfaces of the triples of the first reflection region preferably stand precisely perpendicular on one another. The second reflection region is designed to reflect another part of the incident light falling onto the retroreflection element, independent of the preferred direction, at an observation angle between 0 and 2. The second reflection region ensures that the retroreflection element remains visible at an observation angle up to at least 2, even perpendicular to the preferred direction.

Methods of making tiled articles and molds used to make retroreflective articles. The methods include forming a prism array on a master substrate and forming a replica of the master. A reference edge is formed on the replica, thereby reducing the size of the prism array, yet maintaining a lateral dimension of the replica to maintain ease of handling of the replica. The replica is copied and the reference edge on the copied tiles are exposed, such that the reference edge can be mated and secured face-to-face with a reference edge on other tiles in order to form a tiled article. The tiled article is used as a mold to produce retroreflective articles or can be further duplicated and mated to form larger tiled articles to be used as molds. Tiled articles used as molds and retroreflective articles produced from the molds are also disclosed.

A method for forming a retroreflective prism in a substrate includes inserting and retracting a single point diamond tool through a surface of the substrate while moving the single point diamond tool, the substrate, or both the single point diamond tool and the substrate in a direction of travel along at least one axis to generate a facet in the substrate having a facet face parallel to the direction of travel of at least one of the single diamond point tool or the substrate. The facet face has an angle defined by a chiseling edge of the single point diamond tool. The inserting and retracting is repeated at a plurality of locations on the substrate to form an array of retroreflective microstructures on the surface of the substrate. At least one of the array of retroreflective microstructures is a retroreflective prism having a polygonal projected aperture.