Optical Calibration for 3D Printer Lens Distortion

The patent performs optical calibration before actual 3D printing by projecting calibration patterns through the optical apparatus, capturing images of the projected patterns, and calculating distortion parameters in advance. This preliminary characterization of optical distortion allows the system to pre-compensate for distortion in subsequent printing operations, eliminating the need for real-time correction during material formation.

The patent transforms the projection image parameters by applying distortion correction algorithms that modify pixel coordinates and geometric properties. By changing the parameters of the projected image (position, shape, size of projected features) based on calculated distortion models, the system compensates for lens optical distortion and achieves accurate material formation despite the presence of distorting optical elements.

The patent implements self-calibration capability where the 3D printing system performs its own optical calibration using integrated camera and projection apparatus. The system automatically captures calibration images, processes them to determine distortion parameters, and applies corrections without requiring external calibration equipment or manual intervention. This self-service approach maintains high image fidelity while minimizing additional system complexity.

The patent uses the existing projection apparatus and camera system for multiple purposes: both for normal 3D printing operations and for optical calibration. The same optical machine projects calibration patterns just as it projects printing patterns, and the same camera captures both calibration and printing images. This multi-functionality eliminates the need for separate dedicated calibration equipment, reducing system complexity while maintaining calibration accuracy.