A method of fabricating a nozzle that includes casting and curing a first material using a patterned nip roller to form a first microstructured pattern of discrete microstructures, deforming at least one of the discrete microstructures; replicating the first microstructured pattern, including the at least one deformed discrete microstructure, in a second material different than the first material to make a replicated structure comprising a plurality of blind holes formed in the second material, removing second material of the replicated structure to expose tops of microstructures in the first microstructured pattern, and removing the first material from the replicated structure, resulting in a nozzle having a plurality of through-holes in the second material and corresponding to the first microstructured pattern.