3D Projection Printing Calibration Lookup Tables
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Solution Overview
Problem
3-D projection printing systems face precision issues due to lens malfunctions or assembly tolerances, leading to inconsistent printing quality, particularly in hot environments or during physical stress.
Innovation Solution
A method that uses a combination of look-up tables and interpolation to calibrate 3-D projection printing systems, involving a calibration fixture with a camera and projector to capture sample patterns, transform look-up tables, and store resulting projection tables for precise calibration and printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used, then the system is simpler to operate, but the calibration precision and printing quality deteriorate due to lens malfunctions and assembly tolerances
Solution Approach 1:
The patent performs calibration operations in advance to create lookup tables that compensate for lens deformations and system tolerances before actual printing. The calibration fixture captures sample patterns and generates correction data that is stored and applied during printing, eliminating the need for real-time calibration and ensuring consistent precision.
Solution Approach 2:
The patent introduces a calibration fixture with light-uniform devices and sample patterns as an intermediary tool between the projector and the final workpiece. This fixture mediates the calibration process by providing known reference patterns that enable precise measurement and correction of projection distortions without requiring complex direct measurements.
2Manufacturing precision
If advanced calibration methods with multiple look-up tables are implemented, then printing quality improves, but the calibration process becomes more complex and time-consuming
Solution Approach 1:
The patent performs comprehensive calibration operations in advance to create multiple lookup tables (camera lookup table and projection lookup table) that compensate for various sources of distortion. These tables are generated once and stored for reuse during printing, eliminating the need for repeated calibration and ensuring consistent high-quality results without time loss during production.
Solution Approach 2:
The patent replaces complex real-time mechanical calibration adjustments with pre-computed digital lookup tables that are applied through software interpolation. This substitution of mechanical calibration procedures with computational methods maintains printing quality while significantly reducing calibration time and operational complexity.
3Adaptability or versatility
If a portable calibration fixture is used, then the system becomes more flexible and cost-effective, but the measurement precision may deteriorate compared to fixed installations
Solution Approach 1:
The patent designs a calibration fixture with universal components including a light-uniform device and sample patterns that can be used with different projectors and calibration scenarios. The fixture serves multiple functions: generating reference patterns, uniforming illumination, and capturing calibration data, making it adaptable to various applications while maintaining precision through its standardized design.
Solution Approach 2:
The patent employs parameters such as light uniformity and pattern geometry as controllable variables that can be adjusted and optimized for different calibration scenarios. By carefully controlling these parameters in the portable fixture, the system maintains measurement precision comparable to fixed installations while gaining flexibility and portability.
Data Source
AI summary
The embodiment of the present invention provides a method for a 3-D projection printing system and a system thereof, more particularly to a system adopts both ways of look-up table and interpolation method to calibrate. The embodiment of the present invention provides a portable calibration fixture system and a flexible 3-D projection printing system in order to improve calibration precision, facilitate calibration and printing operations, increase printing effect and save cost.