Multi-Projector Image Projection for High-Resolution Additive Manufacturing
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Solution Overview
Problem
Conventional additive manufacturing systems using digital light processing (DLP) face a decrease in resolution and projected energy density as layer size increases, leading to reduced part accuracy and surface finish due to proportional pixel size enlargement and longer exposure times.
Innovation Solution
An additive manufacturing system utilizing multiple image projectors to project a composite image onto a build area, with a display subsystem controlling each projector to adjust sub-image properties and alignment, employing filters such as irradiance masks, gamma adjustment masks, warp correction filters, and edge blending bars to enhance resolution and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional DLP systems use a single projector to expose an entire layer at once, then print speed is improved, but resolution and projected energy density decrease as layer size increases
Solution Approach 1:
The patent divides the build area into multiple zones, with each projector responsible for one or more zones. This segmentation allows each projector to maintain high resolution for its assigned area while collectively covering the entire build platform, thus resolving the contradiction between large build area and high resolution.
Solution Approach 2:
The patent transitions from a single-projector 2D exposure system to a multi-projector 3D spatial arrangement, where projectors are positioned at different locations and angles around the build area. This dimensional change enables simultaneous high-resolution exposure across the entire build area without compromising print speed.
2Productivity
If conventional DLP systems increase layer size to improve productivity, then print speed increases, but pixel size increases proportionally causing resolution to decrease
Solution Approach 1:
By segmenting the build area into multiple zones covered by different projectors, the system maintains small pixel sizes in each zone even when the overall layer size is large. Each projector projects at full resolution to its assigned zone, preventing the proportional pixel size enlargement that would occur in a single-projector system.
3Area of stationary object
If conventional DLP systems use multiple projectors to cover large build areas, then build area capacity increases, but image distortion and alignment issues worsen
Solution Approach 1:
The system incorporates feedback mechanisms where the controller receives information about projector positions and build area geometry, then dynamically adjusts projection parameters to compensate for distortions. This feedback loop ensures that multiple projectors can cover large build areas while maintaining precise image alignment and geometric accuracy.
Solution Approach 2:
The controller modifies projection parameters such as focus, magnification, and angular orientation for each projector based on its position and the specific build area requirements. These parameter changes allow each projector to optimize its projection for its assigned zone, minimizing image distortion and ensuring accurate alignment across the entire build area.
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
The system achieves high resolution and energy density in large build areas, minimizing image distortions and improving print quality by adjusting sub-image properties and alignment, thus maintaining accuracy and surface finish.
Implementation Method 1
additive manufacturing system utilizing multiple image projectors to project a composite image onto a build area within a resin pool
Data Source
AI summary
An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image includes a plurality of sub-images arranged in an array. The image projection system can project each sub-image onto a portion of the build area using one of the plurality of image projectors, and move the plurality of sub-images to different portions of the build area during an exposure of a layer of an object being manufactured. The properties of a sub-image and the alignment of the position of the sub image within the composite image can be adjusted using a set of filters comprising an irradiance mask that normalizes irradiance, and a warp correction filter that provides geometric correction.