3D Printing Resolution via Sub-Pixel Image Shifting
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Solution Overview
Problem
Existing methods for producing three-dimensional objects by layer-wise solidification of photohardening materials struggle to achieve high resolution in the construction plane without increasing the size of the projection field or moving large masses precisely, which is costly and space-intensive.
Innovation Solution
A process and device that enhance resolution in the sub-pixel range by using a rastered image forming unit to create a sequence of mutually shifted images, producing separate masks/bitmaps for each shift, allowing for improved contour refinement without increasing the resolution of the image forming unit or moving large masses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resolution of the image forming unit is increased to improve construction plane resolution, then the manufacturing precision is improved, but the device complexity and cost increase
Solution Approach 1:
The patent divides a single high-resolution illumination task into multiple sequential passes using a standard-resolution image forming unit. Each pass illuminates a shifted version of the same layer pattern, and the cumulative effect of multiple shifted patterns achieves sub-pixel resolution without requiring a higher-resolution display device.
Solution Approach 2:
The patent introduces a temporal dimension to the illumination process by performing multiple sequential illuminations with shifted patterns. Instead of increasing spatial resolution in the XY plane, the solution uses repeated passes through time, where each pass contributes a shifted pattern that collectively achieves finer resolution than any single pass could provide.
2Manufacturing precision
If the projection field is down-sized to improve surface roughness, then the manufacturing precision is improved, but the construction area is reduced
Solution Approach 1:
The patent segments the illumination process into multiple passes, where each pass uses the full construction area but illuminates slightly shifted patterns. This allows the system to maintain a large construction area while achieving fine surface roughness through the cumulative effect of multiple shifted illuminations rather than requiring a small projection field.
3Manufacturing precision
If large masses are moved precisely to increase projection scale, then the manufacturing precision is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent replaces mechanical movement of large masses with a computational approach. Instead of physically moving the projection system or construction area to achieve precise scaling, the solution uses digital image processing to generate shifted patterns that are illuminated in sequence, achieving the same effect without complex mechanical systems.
4Manufacturing precision
If multiple partial areas are illuminated separately to improve resolution, then the manufacturing precision is improved, but the productivity is reduced
Solution Approach 1:
The patent merges multiple shifted patterns into a single comprehensive illumination sequence. By calculating all the shifted patterns in advance and illuminating them in a coordinated sequence across the full construction area, the system achieves high resolution without requiring multiple separate illuminations of partial areas, thereby maintaining productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for significant resolution enhancement in the construction plane without increasing the construction area or mechanical complexity, enabling precise refinement of outer and inner contours with minimal additional illumination time.
Implementation Method 1
layer-wise solidification of a material solidifiable by the action of electromagnetic irradiation
Data Source
AI summary
The invention relates to a process or 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, wherein the mask is produced using an image forming unit having a prescribed resolution, which is formed from a constant number of image forming elements (pixels) being discrete and being arranged in a spatially mutually fixed manner. For the improvement of the resolution along the outer and inner contours of the sectional areas of the object to be generated layer-wise in the sub-pixel range, a multiple illumination per layer is performed, which consists of a series of multiple images that are mutually shifted in the sub-pixel range in the image/construction plane, wherein a separate mask/bitmap is produced for each shifted image.