New dry photopolymer embossing (DPE) technology was developed recently at Du Pont to replicate highly efficient, deep groove surface relief holographic optical elements (HOEs). DPE technology utilizes Du Pont proprietary materials and processes to replicate with very high degree of precision almost any kind of surface relief or embossed holograms. Very sophisticated embossed HOEs with the width/depth aspect ratio of 1:20 were faithfully replicated by this technology. Dimensions of the replicated grooves or other structures vary from 0.1 micrometers to 3.5 micrometers . Such HOEs can be produced in different geometrical configurations and sizes, which are actually dictated by the master hologram. Embossed HOEs can be fabricated on a plastic film or sheet substrate of different types, thicknesses and shapes. Also glass and other inorganic materials can be used as substrates for these deep groove HOEs. To replicate high quality HOEs the master hologram must be recorded in metal, glass, or other hard surface material. DPE technology may provide substantial technological and economical advantage over existing conventional replication processes, such as injection molding, thermo-embossing, reaction molding or 2P (photo-polymerization) process, in replication of different types of embossed holograms and surface relief HOEs.