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Abstract

A method for making a forming structure. In one embodiment the method comprises the steps of (a) providing a base material having a thickness; (b) providing a laser source; (c) laser etching a plurality of spaced-apart apertures, each aperture extending through the entire thickness of the base material, such that the non-laser-etched portions of the base material define a continuous network; and (d) laser etching the continuous network to remove material in a pattern that defines a plurality of protrusions, each protrusion being generally columnar and pillar-like. The plurality of protrusions can be laser etched first, before laser etching the plurality of spaced-apart apertures. The base material can be cylindrical-shaped and the laser etching can be accomplished in a continuous process by rotating the cylindrical-shaped base material as a laser source is operatively translated while laser etching a path similar to “threads” of a screw.

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First Claim