Microstructure surface can produce excellent functions or performances. However, many microstructures have not been applied widely because of high production costs on industrial scale. The fabrication of large scale cube corner array is still a challenge because of the time-consuming problem. To reduce the manufacture cost of large scale cube corner array, a modified diamond micro chiseling (DMC) method is proposed in this paper. By using the modified method, a cube corner array with the size of 200 µm is successfully fabricated on a 10 mm × 12 mm Ni-P alloy substrate. Experimental observations show that the machined microstructure array has a good homogeneity, and the surface roughness of three cube facets is less than Sa 10 nm. This modified method employs an optimized tool path and targeted design of diamond cutting tool to reduce the processing time. Three facets of cube corner can be chiseled in one process step. By utilizing the optimization strategies, the processing time is reduced to 40 h without deterioration of machining surface quality, which is far less than that consumed by the conventional method, i.e. 95 h. This work presents a method to reduce the manufacturing cost of microstructure surface, through which the microstructure processing can be more cost-effective and widely applied in the future.

微结构表面可以产生优异的功能或性能。然而，由于工业规模的高生产成本，许多微结构尚未得到广泛应用。由于耗时问题，大规模立体角阵列的制造仍然是一个挑战。为了降低大规模立体角阵列的制造成本，本文提出了一种改进的金刚石微凿（DMC）方法。采用改进的方法，在 10 mm × 12 mm Ni-P 合金基板上成功制作了尺寸为 200 µm 的立体角阵列。实验观察表明，加工后的微结构阵列具有良好的均匀性，三个立方体面的表面粗糙度小于Sa10纳米。这种改进的方法采用优化的刀具路径和金刚石刀具的针对性设计，以减少加工时间。一个工艺步骤可以雕刻立体角的三个面。通过利用优化策略，加工时间减少到40小时，而加工表面质量没有恶化，这远远低于传统方法所消耗的时间，即95小时。本工作提出了一种降低微结构表面制造成本的方法，通过该方法可以使微结构加工更具成本效益并在未来得到广泛应用。