Systems and methods for forming a vacuum formed, apertured film with micro-aberrations may be disclosed. For example, a polymer web such as a molten polymer web may be received at an engagement point between a screen with a positive aberration and a roller comprising a surface with a negative depression. The roller may have a diameter of no more than about 5.5 inches. A micro-aberration may be expanded, for example, on a land of the polymer web at the engagement point by inserting the positive aberration on the screen into the negative depression on the surface of the roller at a pressure of about 1.5 to about 3.5 pounds per linear inch (PLI). Additionally, one or more apertures are formed in the polymer web adjacent to a micro-aberration on a land.可被揭露的是用於形成具有微像差之真空形成的孔洞薄膜之系統與方法。例如，可在篩網與滾筒之間的連接點處接收例如模鑄聚合物網的聚合物網，其中篩網具有正像差，滾筒包括具有負壓印的表面。滾筒可具有不大於約5.5英吋的直徑。例如，在每直線英吋(PLI)約1.5至約3.5磅的壓力下，藉由將篩網上的正像差插入滾筒之表面上的負壓印中，可以於聚合物網的平坦處上在連接點處擴展微像差。此外，一或多個孔洞形成於所述聚合物網而與平坦處上的微像差相鄰。
