Integrated microlens array on a transparent film, called an optical film, provides interesting applications for various fields. In a FPD (Flat Panel Display), the optical films are the more important components to improve the efficiency and quality. In this dissertation, a diffuser film which consisted of two different microlens arrays on the two surfaces of a film was developed and used to enhance the brightness and uniformity of a light source. There were also several microlens arrays developed, such as a hexagonal microlens array with gap and gapless, a gapless dual-curvature microlens array and a diffuser film. A process called polygonal microlens array process had been used to manufacture them. It had advantages of mass production, various polygonal shapes and 100% fill-factor. A softer mold of PDMS and a metal mold of NiCo alloy were utilized to replicate the MLAs. In this dissertation, several replication processes were applied to mass product and to find out which one is more suitable for the diffuser film. In this dissertation, the results of different shapes and dimensions of microlens arrays showed various light distribution. Therefore, for searching a more suitable and novel layout of a diffuser, Taguchi Method with simulation was used to design the layout of a diffuser film before fabrication process. Finally, a diffuser film was measured and demonstrated its optical effects. According to the results of measurement and simulation, the average intensity and the S/N ratios were shown. The trend of simulation and measurement was also similar.