Improving 3D Printing Resolution with Gray Scale Exposure
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Summary
Problems
Existing three-dimensional object fabrication techniques using digital light projectors face limitations in achieving smooth edges and high resolution due to the fixed number of pixels, leading to inaccurate feature placement and rough surface finishes, especially in solid imaging applications where two-dimensional image projection methods are applied to three-dimensional objects.
Innovation solutions
The method involves varying the gray scale exposure levels or illumination time of each pixel to control the polymerization boundary of a solidifiable photopolymer build material, allowing for improved edge smoothness and feature accuracy without requiring additional mechanical hardware, by optimizing light intensity distribution and focus across the image plane.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If fixed pixel projection is used in digital light projectors, then device complexity is reduced, but manufacturing precision and surface finish deteriorate due to rough edges and poor feature definition
Why choose this principle:
The patent varies the illumination time parameter for different pixels to control the polymerization boundary. By adjusting exposure time rather than relying solely on fixed pixel boundaries, the system achieves smoother edges and better feature definition without changing the physical pixel structure of the projector.
Principle concept:
If fixed pixel projection is used in digital light projectors, then device complexity is reduced, but manufacturing precision and surface finish deteriorate due to rough edges and poor feature definition
Why choose this principle:
The patent employs sequential illumination of different pixel groups with varying exposure times. This periodic action allows different regions of the projected image to receive differentiated light dosing, enabling precise control over polymerization boundaries and achieving sub-pixel resolution edge smoothness.
Application Domain
Data Source
AI summary:
The method involves varying the gray scale exposure levels or illumination time of each pixel to control the polymerization boundary of a solidifiable photopolymer build material, allowing for improved edge smoothness and feature accuracy without requiring additional mechanical hardware, by optimizing light intensity distribution and focus across the image plane.
Abstract
A solid imaging apparatus and method employing levels of exposure varied with gray scale or time or both of digitally light projected image of a cross-section of a three-dimensional object on a solidifiable photopolymer build material. The gray scale levels of exposure of projected pixels permits the polymerization boundaries in projected boundary pixels to be controlled to achieve preserved image features in a three-dimensional object and smooth out rough or uneven edges that would otherwise occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Software is used to control intensity parameters applied to pixels to be illuminated in the image projected in the cross-section being exposed in the image plane.