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.