USRE43955E1 - Process for the production of a three-dimensional object with resolution improvement by pixel-shift - Google Patents
Process for the production of a three-dimensional object with resolution improvement by pixel-shift Download PDFInfo
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- USRE43955E1 USRE43955E1 US13/230,270 US201113230270A USRE43955E US RE43955 E1 USRE43955 E1 US RE43955E1 US 201113230270 A US201113230270 A US 201113230270A US RE43955 E USRE43955 E US RE43955E
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
Definitions
- the invention related to a process and a device for the production of a three-dimensional object by layer-wise solidification of a photohardening material by mask illumination by means of a rastered image forming unit having constant resolution, wherein the resolution within the image/construction plane shall be improved in the sub-pixel range.
- This invention relates to processes wherein the layer to be generated is based on illumination by means of a rastered mask, wherein the smallest physical resolution within the mask is provided by the size of a pixel.
- IPC B29C67/00 “Rapid Prototyping apparatus and method of Rapid Prototyping” of Dicon AS (DK), (application)
- U.S. Pat. No. 6,180,050 describes a linear scan technique for layer-wise solidification in the production of three-dimensional objects.
- the resolution is enhanced by scanning, in X-direction, an illumination head having an array of optical fibers, which are displaced in the Y-direction.
- the resolution of the material layer to be hardened is in direct dependency from the resolution of an image forming process.
- an intermediary positioned optic additionally determines the scale of the projected or solidifiable layer.
- the resolution per area unit in the image/construction plane thus is dependent on a) the resolution of the image forming unit or the smallest element, called pixel, and their relative mutual distances, called pixel-pitch, and b) the projection scale.
- the surface roughness of the construction part thus is determined by the smallest volume unit of one voxel (volume-pixel), the size of which is composed of the projected pixel area in XY and the layer thickness in Z.
- the resolution of the layer thickness is prescribed by the smallest resolution (step level) of the actuator in Z, in order to move the support platform. Resolutions already down to the one-figure ⁇ m range is achievable hereby. If an even lower surface roughness of the construction part shall be realized, the projection field and concurrently the width of the pixel area must be down-sized.
- the projection m.H. of a multi-media projector shall be mentioned here; with a resolution of XGA (1024 ⁇ 768 image dots), a pixel of 17 ⁇ m and pixel-pitch of 17.9 ⁇ m, one realizes, at a projection to 275 mm ⁇ 206 mm with an enhancement factor of the projection optic of 15, a resolution in the image/construction plane and thus in the layer to be solidified of approximately 100 dpi, which corresponds to a pixel size in the projection plane of about 0.254 mm ⁇ 0.254 mm.
- the resolution in the construction plane is equivalent to the resolution in the image forming unit.
- the present invention provides a process for the production of a three-dimensional object by layer-wise solidification of a material solidifiable by the action of electromagnetic irradiation by means of mask illumination, wherein the mask is produced by an image forming unit having a prescribed resolution, which mask is formed from a constant number of image forming elements (pixel) being discrete and spatially arranged in a fixed manner to each other, characterized in that, for improving the resolution in the sub-pixel range along the outer and inner contours of the sectional areas of the object to be generated layer-wise, a multiple illumination is carried out for each layer which consists of a sequence of a multitude of images mutually shifted in the sub-pixel range in the image/construction plane, wherein a separate mask/bitmap is produced for each shifted image.
- the invention also provides a device for the production of a three-dimensional object by layer-wise solidification of a material which is solidifiable under the application of electromagnetic irradiation by means of mask illumination, whereby the irradiation necessary for hardening is imaged into the image/construction plane
- the device comprises a rastered, image forming unit for the selective illumination, which is embodied either by line or by matrix, characterized in that the image forming unit composes the image from individual image dots (pixels) and thus forms a rastered mask (bitmap), wherein the pixels are arranged within the plane in a manner mutually fixed to each other, and that the image forming unit and/or an imaging optic which is provided between the image forming unit and the image/construction plane is/are designed such that a sequence of a multitude of images, which are mutually shifted in a sub-pixel range, can be created, wherein a separate mask/bitmap can be produced for each shifted image.
- the resolution in the image/construction plane is improved in the sub-pixel range by means of “pixel-shift”.
- the present invention deals with the layer-wise solidification for the production of three-dimensional objects or construction elements by means of solidification of material (specifically by means of photo-polymerization) through mask projection, but not with a conventional layer-wise solidification through (linear) scan technique.
- This can be carried out according to the invention very efficiently and advantageously by using a two-dimensionally set array as the image generating element, wherein raster and/or resolution is(are) preset, e.g. by means of a set micro mirror array.
- VAROS Very Refraction Optical System
- Double-CCD Double-CCD
- the resolution or the number of image dots of the rastered, image forming unit itself does not have to be increased in order to realize an improvement in the solution within the construction plane.
- the illumination does not occur in correspondingly down-sized, adjacently disposed partial areas, whereby the construction/illumination period for the whole area would be increased by the number of partial areas; rather, the projection/illumination occurs over the whole construction area.
- the level of resolution improvement within the construction plane can be chosen freely.
- FIG. 1 schematically shows a basic device for the generation of a three-dimensional object 3 by layer-wise hardening of a photohardening material 4 by means of mask projection 8 , wherein the projection unit 1 is present, with an image forming optic 2 , above the basin 6 which is filled with photohardening material 4 , and wherein the object 3 solidifies layer-wise on a support plate 5 , which can be moved within the basin 6 in vertical direction.
- the irradiation necessary for hardening is projected into the image/construction plane 7 .
- the illumination is carried out by means of a rastered image forming unit, which is formed in the form of a matrix.
- the image thus is composed of single image dots (pixels) and thus forms a rastered mask (bitmap), wherein the pixels are arranged in a specially fixed manner to each other within the plane.
- FIG. 8-12 show the principle of a mask generation (bitmapping) of a sectional area of a three-dimensional object in the starting position ( FIG. 8 ) and in various states of the bitmap which are displaced (shifted) in the sub-pixel range ( FIG. 9-11 ), as well as the overlapping of all bitmaps ( FIG. 12 ).
- the sectional area i.e. the outer and inner contours, are prescribed by a sectorial trail 11 , which is superimposed by a rastered area (bitmap) 12 , the solution of which exactly corresponds to the resolution of the discrete elements (pixels) within the projected image 8 which is formed by the image forming matrix.
- Vectorial trail 11 and bitmap 12 thus exist within a superior-ordered XY-coordinate system 10 .
- FIG. 8 shows the bitmap in its starting position. By means of a specific algorithm, the active pixels 13 which describe the sectional area within the bitmap 12 in its starting position are calculated.
- bitmap 14 is shifted within the sub-pixel range relative to the sectional area by delta X, whereby a new distribution of active pixels 15 is produced.
- FIG. 10 shows a shift of bitmap 16 relative to the sectional area by delta Y with active pixels 17 .
- FIG. 11 shows a diagonal shift of bitmap 18 relative to the sectional area by delta X and delta Y with active pixels 19 .
- FIG. 12 all bitmaps 12 , 14 , 16 and 18 with their active pixels 13 , 15 , 17 and 19 are shown superimposed, whereby a resolution improvement in the (outer) contour portion of the sectional area is clearly noticeable.
- a simplified process for resolution improvement is achieved by the measure that only bitmap 12 of the started position ( FIG. 8 ) and bitmap 18 of the diagonal shift ( FIG. 11 ) are superimposed. In this case, the bitmap or the image does only have to be shifted in one direction along the diagonal of the pixels.
- a multiple (at least twice) of masks or bitmaps having different sub-pixel shifts can be generated and superimposed.
- bitmaps of each individual layer necessary for mask projection are generated from layer data, in which the outer and inner contours of the respective object section is represented in vectorial trails (as e.g. defined in the data format CLI).
- a separate bitmap is generated by transforming the XY coordinates of the vectors (for the outer and the inner contours) of the layer data by the respective shift-offset in XY (in the sub-pixel range), and by superposing them over the bitmap-raster, and thus by calculating a new distribution of active pixels for each shift.
- the projected light output per pixel can be varied by “grey scaling” within a projection mask, in order to selectively influence the hardening level in one layer thereby. This is particularly meaningful in order to raise the light output of the pixels of the contour because only partial superimposition of the respective pixels of the contour are produced here due to the sub-pixel shift over individual bitmaps (in the areas within the contours a complete superimposition of the pixels of each individual bitmap is ensured).
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Optics & Photonics (AREA)
- Exposure And Positioning Against Photoresist Photosensitive Materials (AREA)
- Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
Abstract
Description
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- a) Projection unit (on the basis of DLP®/DMD®, LCD, ILA®, etc.)
- b) LD-display (reflective, transmissive)
- c) LED-, or laser-diode-line/-matrix (which is moved in XY-plane over the layer)
- d) Line or matrix (which is moved in XY-plane over the layer) based on MEM-technology (light-valve).
PCT Application 02 008 019.8 “Device for the production of a three-dimensional object” of Envision Technologies GmbH, April 2002.
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- a) without having to carry out an illumination in partial areas to be composed together, and
- b) without enhancing the resolution of the rastered image-forming unit itself.
- (a) said image forming unit is formed of a constant number of image forming elements (pixel) being discrete and spatially arranged to each other in a two-dimensional matrix;
- (b) a sequence of at least 2 images mutually shifted in the sub-pixel range is carried out in the image/construction plane, corresponding to the resolution of the image forming unit and under consideration of the corresponding sub-pixel shift;
- (c) the sectional area, i.e. outer and inner contours, are defined by vectorial trails which are superimposed by technical image processing by a rastered area (bitmap), the resolution of which exactly corresponds to the resolution of the discrete elements (pixels) in the image forming unit and thus in the image in the construction plane, wherein the superimposition of vectorial trails and bitmap takes place in a superior-ordered XY-coordinate system, and wherein the active pixels are calculated by a specific algorithm in order to define the sectional area in the form of a rastered mask;
- (d) the mask generation (bitmapping) of each sectional area of a three-dimensional object is carried out in the starting position and in various states displaced (shifted) in the sub-pixel range in XY, and that a total image having an enhanced resolution in the contour portion corresponding to the pixel shift is obtained by the superimposition of these bitmaps per sectional area;
- (e) a bitmap is produced which is shifted relative to the sectional area by delta X, which results in a new distribution of active pixels;
- (f) a bitmap is produced which is shifted by delta Y in the sub-pixel range relatively to the sectional area, which results in a new distribution of active pixels;
- (g) a bitmap is produced which is shifted along the pixel diagonal by delta X and delta Y relatively to the sectional area, which results in a new distribution of active pixels;
- (h) the total illumination of an individual layer results from the sum of the partial illuminations of the masks/bitmaps shifted in the sub-pixel range;
- (i) for each layer of the object, a multitude of masks or bitmaps having different sub-pixel shifts in XY can be generated and can be illuminated serially for each layer to be hardened;
- (j) a simplified process for resolution improvement is achieved in such a manner that only the bitmap of the starting position and the bitmap of the diagonal-shift by a half pixel-diagonal are produced and are subsequently illuminated for each layer to be hardened;
- (k) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted manner in the sub-pixel range for the purpose of selectively hardening the material layer, the image forming unit is tilted for each shifted bitmap such that the desired shift of the image in the sub-pixel range in the image/construction plane is achieved;
- (l) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted manner in the sub-pixel range for the purpose of selectively hardening the material layer, the image forming unit for each shifted bitmap is shifted by the corresponding sub-pixel range in X and Y, that is parallel in plane to the image/construction plane;
- (m) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted manner in the sub-pixel range for the purpose of selectively hardening the material layer, the image forming projection unit is maintained fixed in its position, and the imaging optic of the projection unit is tilted for each shifted bitmap such that the desired shift of the image in the image/construction plane in the sub-pixel range is achieved;
- (n) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted mariner in the sub-pixel range for the purpose of selectively hardening the material layer, the image forming projection unit is maintained fixed in its position, and the imaging optic of the projection unit is shifted for each shifted bitmap in XY such that the desired shift of the image in the image/construction plane in the sub-pixel range is achieved;
- (o) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted manner in the sub-pixel range for the purpose of selectively hardening the material layer, the projection unit is tilted for each bitmap via actuators such that the projected image in the construction plane is shifted in the corresponding sub-pixel range in X and Y;
- (p) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted manner in the sub-pixel range for the purpose of selectively hardening of the material layer, a cardanic mounted transparent, plane-parallel plate is arranged between the projection unit and the image/construction plane, which plate shifts, by rotation around two axis (XY) which are present in-plane parallel to the image/construction plane, the projection beam path and thus the image in the image/construction plane in the sub-pixel range in X and Y;
- (q) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted mariner in the sub-pixel range for the purpose of selectively hardening of the material layer, a transparent plane-parallel plate is arranged between the projection unit and the image/construction plane, which plate shifts, by rotation around an axis parallel to a pixel-diagonal, the projection beam path and thus the image in the image/construction plane in the sub-pixel range along the pixel diagonal which is orthogonal thereto;
- (r) for the shifted imaging of the rastered masks/bitmaps in the construction plane which are produced in a shifted manner in the sub-pixel range for the purpose of selectively hardening of the material layer, the projection unit is maintained fixed in its position, and the projection beam is deflected via a mirror into the image/construction plane, wherein the deflecting mirror is provided with an adjustment possibility (cardanic support) by which the projection beam for each shifted bitmap can be deflected such that a shift of the image in the sub-pixel range is achieved in the image-/construction plane; and
- (s) the projected light output for each pixel is varied by “grey scaling” within a projection mask, in order to selectively influence the hardening level in a layer thereby and thus to raise the light output of the contour-pixel relative to the light output of the area-pixel, in order to compensate the partial illumination due to partial superimposition of a contour-pixel by the sub-pixel shift of the individual bitmap in the contour portion.
- (1) said image forming unit for the selective illumination is embodied by a matrix;
- (2) a series of at least 2 images, which are mutually shifted in a sub-pixel range, can be created in the image/construction plane
- (3) said image forming unit is a projection unit;
- (4) said image forming unit is a line, particularly a matrix having discretely emitting elements for image formation;
- (5) the device is provided with actuators in order to shift the whole image forming unit per partial image in a plane-parallel manner towards the image/construction plane in XY in the sub-pixel range;
- (6) the device is provided with actuators which can tilt the image forming unit per shift-generated bitmap such that the individual, shift-generated bitmaps in the image/construction plane are imaged in a manner shifted in the sub-pixel range;
- (7) between the image forming unit and the image/construction plane, a mirror is arranged as an imaging optic and is cardanically mounted and is rotatable via actuators such that the beam path is deflected into the image plane and that the individual, shift-generated bitmaps in the image-/construction plane can be imaged in a correspondingly shifted manner in the sub-pixel range;
- (8) between the image forming unit and the image/construction plane, a transparent plate having mutual plane-parallel surfaces is arranged as an imaging optic and can be tilted by means of one or more actuators such that the beam path is shifted and that the individual, shift-generated bitmaps in the image-/construction plane are imaged in a manner shifted in the sub-pixel range;
- (9) the image forming projection unit is maintained fixed in its position and that the imaging optic can be shifted in XY in a sub-pixel range of the image forming unit via actuators such that the desired shift of the image in the image-/construction plane in a sub-pixel range is achieved; and
- (10) the image forming projection unit is maintained fixed in its position and that the imaging optic can be tilted via actuators such that the desired shift of the image in the image/construction plane in the sub-pixel range is achieved.
- 1) In
FIG. 2 , theimage forming unit 1 is tilted for each shifted bitmap such that the desired shift of the image in the sub-pixel range within the image/construction plane is achieved. - 2) In
FIG. 3 , theimage forming unit 1 is shifted for each shifted bitmap by the corresponding sub-pixel level in X and 7, that is parallel in plane to the image/construction plane, by means of actuators. - 3) In
FIG. 4 , the image forming projection unit is maintained fixed in its position, Theimaging optic 2 is tilted for each shifted bitmap such that the desired shift of the image within the image-/construction plane in the sub-pixel range is achieved. - 4) In
FIG. 5 , the image forming projection unit is maintained fixed in its position. Theimaging optic 2 is moved for each shifted bitmap in XY such that the desired shift of the image within the image-/construction plane in the sub-pixel range is achieved. - 5) Particular cases for imaging by image-ward telecentric irradiation path, by an image-ward approximately telecentric irradiation path, and by teleobjectives having long focal length, in order to keep optical errors (angle errors, distortion) small:
- a) In
FIG. 5 , theprojection unit 1 is tilted for each shifted bitmap via actuators such that theprojection image 8 within the image/construction plane 7 is shifted in the corresponding sub-pixel range in X and Y. - b) In
FIG. 6 , a cardanically mounted transparent, plane-parallel plate 9 (glass plate) is disposed between theprotection unit 1 and the image/construction plane 7, which plate shifts theprotection irradiation path 8 and thus the image within the image/construction plane 7 in the sub-pixel range in X and 7 by means of rotation around two axis (XY), which are located parallel in plane to the image/construction plane. - c) In
FIG. 7 , theprojection unit 1 is maintained fixed in its position. Theprojection beam 8 is deflected via amirror 10 into the image/construction plane 7. The deflectingmirror 10 is provided with an adjustment possibility (cardanic support), by which the protection beam can be deflected for each shifted bitmap such that a shift of the image within the image/construction plane 7 in the sub-pixel range is achieved.
- a) In
Claims (24)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US13/230,270 USRE43955E1 (en) | 2004-05-10 | 2011-09-12 | Process for the production of a three-dimensional object with resolution improvement by pixel-shift |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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US56989304P | 2004-05-10 | 2004-05-10 | |
DE102004022961 | 2004-05-10 | ||
DE102004022961A DE102004022961B4 (en) | 2004-05-10 | 2004-05-10 | Method for producing a three-dimensional object with resolution improvement by means of pixel shift |
US11/126,068 US7790093B2 (en) | 2004-05-10 | 2005-05-09 | Process for the production of a three-dimensional object with resolution improvement by “pixel-shift” |
US13/230,270 USRE43955E1 (en) | 2004-05-10 | 2011-09-12 | Process for the production of a three-dimensional object with resolution improvement by pixel-shift |
Related Parent Applications (1)
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US11/126,068 Reissue US7790093B2 (en) | 2004-05-10 | 2005-05-09 | Process for the production of a three-dimensional object with resolution improvement by “pixel-shift” |
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USRE43955E1 true USRE43955E1 (en) | 2013-02-05 |
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US13/230,270 Active 2029-05-25 USRE43955E1 (en) | 2004-05-10 | 2011-09-12 | Process for the production of a three-dimensional object with resolution improvement by pixel-shift |
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US (1) | USRE43955E1 (en) |
EP (2) | EP1744871B1 (en) |
JP (1) | JP5184080B2 (en) |
DE (1) | DE502005004008D1 (en) |
HK (1) | HK1138235A1 (en) |
WO (1) | WO2005110722A1 (en) |
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JP2007536131A (en) | 2007-12-13 |
EP1894705B1 (en) | 2010-08-25 |
WO2005110722A1 (en) | 2005-11-24 |
JP5184080B2 (en) | 2013-04-17 |
EP1744871B1 (en) | 2008-05-07 |
DE502005004008D1 (en) | 2008-06-19 |
EP1894705A3 (en) | 2008-12-03 |
HK1138235A1 (en) | 2010-08-20 |
EP1744871A1 (en) | 2007-01-24 |
EP1894705A2 (en) | 2008-03-05 |
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