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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 PDF

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Publication number
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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United States
Prior art keywords
image
shifted
sub
bitmap
pixel
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US13/230,270
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English (en)
Inventor
Alexandr Shkolnik
Hendrik John
Ali El-Sibiani
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Envisiontec GmbH
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Envisiontec GmbH
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Priority claimed from DE102004022961A external-priority patent/DE102004022961B4/de
Application filed by Envisiontec GmbH filed Critical Envisiontec GmbH
Priority to US13/230,270 priority Critical patent/USRE43955E1/en
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Publication of USRE43955E1 publication Critical patent/USRE43955E1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/106Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124Processes 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
    • B29C64/129Processes 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y50/00Data acquisition or data processing for additive manufacturing
    • B33Y50/02Data 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)
US13/230,270 2004-05-10 2011-09-12 Process for the production of a three-dimensional object with resolution improvement by pixel-shift Active 2029-05-25 USRE43955E1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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
US56989304P 2004-05-10 2004-05-10
DE102004022961 2004-05-10
DE102004022961A DE102004022961B4 (de) 2004-05-10 2004-05-10 Verfahren zur Herstellung eines dreidimensionalen Objekts mit Auflösungsverbesserung mittels 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)

Application Number Title Priority Date Filing Date
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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US (1) USRE43955E1 (fr)
EP (2) EP1744871B1 (fr)
JP (1) JP5184080B2 (fr)
DE (1) DE502005004008D1 (fr)
HK (1) HK1138235A1 (fr)
WO (1) WO2005110722A1 (fr)

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US9205601B2 (en) 2013-02-12 2015-12-08 Carbon3D, Inc. Continuous liquid interphase printing
US9360757B2 (en) 2013-08-14 2016-06-07 Carbon3D, Inc. Continuous liquid interphase printing
US9453142B2 (en) 2014-06-23 2016-09-27 Carbon3D, Inc. Polyurethane resins having multiple mechanisms of hardening for use in producing three-dimensional objects
US9486964B2 (en) 2012-05-03 2016-11-08 B9Creations, LLC Solid imaging apparatus with improved part separation from the image plate
US9498920B2 (en) 2013-02-12 2016-11-22 Carbon3D, Inc. Method and apparatus for three-dimensional fabrication
US9914265B2 (en) 2012-12-20 2018-03-13 Kulzer Gmbh Method for producing a homogeneous light distribution
US10316213B1 (en) 2017-05-01 2019-06-11 Formlabs, Inc. Dual-cure resins and related methods
WO2019145795A2 (fr) 2018-01-26 2019-08-01 Cellink Ab Systèmes et procédés d'évaluations optique de l'imprimabilité de bio-encre
US10391708B2 (en) 2013-07-16 2019-08-27 Schultheiss Gmbh Method and device for producing a three-dimensional object and exposure mask generating apparatus
US10471699B2 (en) 2014-06-20 2019-11-12 Carbon, Inc. Three-dimensional printing with reciprocal feeding of polymerizable liquid
US11186736B2 (en) 2018-10-10 2021-11-30 Cellink Ab Double network bioinks
CN115139528A (zh) * 2022-06-10 2022-10-04 深圳市纵维立方科技有限公司 一种3d打印中的切片处理方法、装置、存储介质和电子设备
US11679555B2 (en) 2019-02-21 2023-06-20 Sprintray, Inc. Reservoir with substrate assembly for reducing separation forces in three-dimensional printing
US11747732B2 (en) 2017-11-02 2023-09-05 Jabil Inc. Digital masking system, pattern imaging apparatus and digital masking method
US11786711B2 (en) 2013-08-14 2023-10-17 Carbon, Inc. Continuous liquid interphase printing
US11826951B2 (en) 2019-09-06 2023-11-28 Cellink Ab Temperature-controlled multi-material overprinting

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DE102004022606A1 (de) 2004-05-07 2005-12-15 Envisiontec Gmbh Verfahren zur Herstellung eines dreidimensionalen Objekts mit verbesserter Trennung ausgehärteter Materialschichten von einer Bauebene
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DE102006019964C5 (de) 2006-04-28 2021-08-26 Envisiontec Gmbh Vorrichtung und Verfahren zur Herstellung eines dreidimensionalen Objekts mittels Maskenbelichtung
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