Spliced Light Source Calibration for Seamless DLP 3D Printing
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Solution Overview
Problem
The existing 3D printing technologies using digital light processing (DLP) face limitations in projection accuracy and format size, leading to splicing defects such as seams and bumps when multiple optical machines are spliced, affecting the quality of printed parts.
Innovation Solution
A calibration method for splicing light source modules involves optical calibration and accuracy inspection in overlapping areas, ensuring precise alignment and correction of pixel information to avoid splicing ripples and disturbances, thereby improving projection and 3D printing effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple DLP optical machines are spliced to increase projection format size, then the printing area is expanded, but splicing defects such as seams, bumps, and information loss occur at the edges
Solution Approach 1:
The patent divides the projection system into multiple independent light source modules, each projecting a separate format. By segmenting the overall projection task into manageable parts that can be independently calibrated and then spliced together, the system achieves both large projection area and high splicing precision through the overlapping calibration method
Solution Approach 2:
The patent performs optical calibration processing on each light source module before actual projection, using an overlapping area between adjacent modules to pre-align and correct positional deviations. This preliminary calibration action ensures that when modules are spliced together, they achieve sub-pixel level accuracy without seams or bumps
2Area of stationary object
If the projection format size is increased in DLP technology, then the printing area is expanded, but the projection accuracy decreases
Solution Approach 1:
The patent introduces a new dimensional approach by creating an overlapping calibration area between adjacent light source modules. This overlapping dimension provides additional reference points for calibration, enabling the system to maintain high projection accuracy even when the overall projection format size is increased through multiple spliced modules
3Adaptability or versatility
If multiple light source modules are spliced to overcome DMD optical power limits, then the projection capability is enhanced, but optical aberrations cause splicing defects
Solution Approach 1:
The patent implements a feedback mechanism where the overlapping area between adjacent light source modules serves as a reference for detecting and correcting positional deviations. By continuously monitoring and adjusting based on the overlapping region alignment, the system eliminates splicing defects such as seams and bumps while maintaining enhanced projection capability through multiple modules
Data Source
AI summary
Provided are a calibration method for splicing light source modules, a projection method, a 3D printing method, a calibration apparatus, a 3D printer, and a non-volatile computer-readable storage medium. There are at least two light source modules. The calibration method includes: performing optical calibration processing on each of the light source modules, wherein a splicing overlapping area is present in projection regions of the light source modules subjected to optical calibration processing; and performing, on the basis of the splicing overlapping area, calibration accuracy inspection on each of the light source modules subjected to optical calibration processing.