A vacuum forming roll is assembled from a large plurality of radially extensive
interlocking segments. Each segment forms a small angular part of a circumference
about the roll, and has a relatively small thickness parallel to the longitudinal
axis of the roll. The segments are preferably stacked together in an interlocking
fashion to form a continuous roll consisting of a plurality of angularly offset
circumferential rings. In a preferred embodiment, the segments are formed by manufacturing
a small mold designed to form a single segment. This mold may, for exemplary purposes,
be an injection mold. The roll mold segments may then be produced quickly and easily
using an injection molding process, which, as aforementioned, is efficient for
the production of a large number of identical components. The roll mold segments
are then assembled to form the roll mold, which is in turn used to shape and perforate
a plastic film and thereby manufacture an improved landscape fabric economically.
A variety of shapes, geometries and operations for the segments and molds are described.