Pixel Boundary Alignment in Digital Light Processing Printers
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Solution Overview
Problem
In additive manufacturing, the misalignment of parts with interpixel boundaries leads to uneven application of software adjustments, resulting in large inter-part variation, increased scrap rates, and higher costs.
Innovation Solution
A method is developed to align parts with pixel boundaries in digital light processing printers, ensuring that software adjustments are applied uniformly across the build area by establishing an absolute location of pixels in the x/y plane and deriving pixel boundaries for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If parts are positioned using software without aligning to pixel boundaries, then parts can be printed across the build area, but software adjustments are applied unevenly resulting in inter-part variation
Solution Approach 1:
The patent applies preliminary action by pre-aligning part origins to pixel boundaries before the printing process begins. The method establishes an absolute coordinate system based on pixel boundaries and positions all parts to align with these boundaries in advance, ensuring that software adjustments (scaling, antialiasing, pixel shifting) are applied uniformly to all parts throughout the build area, thereby eliminating inter-part variation.
2Manufacturing precision
If software adjustments are applied to models, then parts can be printed with desired dimensions, but misalignment with pixel boundaries causes uneven application of scaling, antialiasing and pixel shifting
Solution Approach 1:
The patent applies local quality by ensuring that each part is positioned at a specific location aligned with pixel boundaries, giving each part a consistent local coordinate reference. This localized alignment at pixel boundaries ensures that software adjustments are applied uniformly to every part's local coordinate system, making the application of scaling, antialiasing, and pixel shifting consistent across all parts regardless of their position in the build area.
3Adaptability or versatility
If parts are not aligned to pixel boundaries, then positioning is flexible, but surface morphology shows irregularities and variation across parts
Solution Approach 1:
The patent applies dimensionality change by introducing a new reference dimension - the pixel boundary grid - that overlays the physical build area. Instead of relying solely on continuous software coordinate positioning, the method adds a discrete pixel-based dimensional reference that all parts must align to. This additional dimensional constraint (alignment to pixel boundaries) standardizes the positioning across all parts, ensuring uniform surface morphology while maintaining the ability to position parts throughout the 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
This approach minimizes inter-part variation by ensuring consistent application of scaling, antialiasing, and pixel shifting, resulting in more uniform surface morphology and reduced scrap rates, thereby lowering the cost of printed parts.
Implementation Method 1
selective curing and hardening of radiation curable (photocurable) liquid resins
Data Source
AI summary
A method of aligning a part in digital light processing printer and a part made therefrom. The method includes: establishing an absolute location of a pixel in an x/y plane; deriving a pixel boundary from the absolute location; aligning a three dimensional model with the pixel boundary across a build area of the printer; and printing the part using digital light processing. The part has a surface with a uniform surface morphology.