A method of forming pigment flakes includes using a deposition substrate having a plurality of regions some of the regions are raised or lowered so that there is a level difference between each two adjacent regions. A coating deposited onto this substrate breaks along region borders when it is separated from the substrate. In one embodiment, the substrate includes first and second regions, wherein each of the first regions is in an abutting relationship with at least one of the second regions. All the first regions are at a first level and all the second regions are at a second level, and the difference between the first and second levels is greater than a predetermined value. The first and second regions are preferably square-shaped regions for manufacturing square flakes with practically no debris.
