a method for forming microspheres on a microscopic level comprises the steps of defining holes through a substrate , disposing a sheet of thermally formable material onto the substrate covering the holes , heating the sheet of thermally formable material until a predetermined degree of plasticity is achieved , applying fluidic pressure through the holes to the sheet of thermally formable material , while the sheet of glass is still plastic , and forming microspheres on the substrate in the sheet of thermally formable material by means of continued application of pressure for a predetermined time . the invention also includes a substrate having a plurality of holes defined therethrough , a layer of thermally formable material disposed onto the substrate covering the plurality of holes , and a plurality of microspheres thermally formed in the layer by means of applied pressure through the holes when it has been heated to a predetermined degree of plasticity .