Volumetric 3D Printing Alignment Using Software Image Warping
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Solution Overview
Problem
Conventional volumetric additive manufacturing methods face challenges in achieving precise alignment due to mechanical tolerances and environmental factors, leading to misalignment and defects in 3D objects, with existing solutions being time-consuming, requiring skilled operators, or involving complex hardware setups.
Innovation Solution
The method calculates and adjusts angular and spatial misalignments by modifying two-dimensional images projected by a light projector based on detected misalignments between the projector, rotation stage, and vial, using a digital micromirror device or spatial light modulator, to ensure accurate alignment and object formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration techniques are used to address alignment issues, then alignment accuracy is improved, but time consumption increases and operational complexity increases
Solution Approach 1:
The patent replaces manual mechanical calibration with an automated image processing system. The system captures images of the vial during rotation, automatically detects the vial's position and orientation, calculates misalignment parameters, and generates corrected projection images. This automated approach eliminates time-consuming manual adjustment while maintaining high alignment accuracy through computational methods.
Solution Approach 2:
The system performs self-calibration by automatically detecting its own misalignment state through image capture and processing. The image processing algorithm independently determines the vial's rotational position and projector alignment without requiring external intervention or skilled operators, enabling the system to correct its own alignment issues autonomously.
2Manufacturing precision
If automated sensor-based systems are used to detect misalignment, then precision is improved, but device complexity and cost increase
Solution Approach 1:
Instead of using complex sensor systems to directly measure alignment, the patent creates a visual copy (image) of the vial during rotation. The image processing system analyzes this visual representation to infer alignment parameters. This indirect measurement approach uses simple imaging hardware rather than complex sensors, reducing system complexity while achieving high precision through computational analysis of the captured images.
Solution Approach 2:
The patent introduces an intermediary image processing system between the physical alignment state and the projection control. Rather than directly sensing alignment with complex sensors, the system captures intermediate visual data (images of the vial) and processes this data to determine alignment parameters. This intermediary approach simplifies the hardware requirements while maintaining precise alignment control through software-based computation.
3Manufacturing precision
If mechanical adjustments are made to correct misalignment, then alignment accuracy is improved, but operational complexity and skill requirements increase
Solution Approach 1:
The patent substitutes mechanical adjustment operations with automated image processing and computational correction. Instead of requiring operators to physically adjust the projector or vial position, the system captures images, processes them to determine misalignment, and generates corrected projection images through software algorithms. This eliminates the need for skilled mechanical adjustment while maintaining high alignment accuracy.
Solution Approach 2:
The system performs self-correction of alignment issues without requiring operator intervention. The automated image processing algorithm independently analyzes the captured images, calculates the necessary corrections, and generates adjusted projection images. This self-service capability removes the dependency on skilled operators for alignment correction, making the process simple and accessible to users with minimal expertise.
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 enhances the accuracy and confidence in producing 3D objects by correcting misalignments through software-based image warping, reducing the need for mechanical adjustments and expertise, thus improving precision and efficiency.
Implementation Method 1
Volumetric additive manufacturing (VAM) has emerged as a promising technique for fabricating complex three-dimensional (3D) objects by projecting two-dimensional (2D) images into a photopolymerizable resin
Data Source
AI summary
The present disclosure relates to a volumetric additive manufacturing method for generating multiple two-dimensional images of a three-dimensional model for a 3D object. The method involves identifying a projector line on an alignment plane and capturing images of a vial while rotating a rotation stage to which the vial is attached. The captured images are analyzed to determine an axis of rotation and a vial line on the alignment plane. A misalignment shift and angle are calculated based on the projector line, axis of rotation, and vial line. The plurality of 2D images intended for projection by the projector are then modified according to the calculated projector misalignment angle and shift, ensuring accurate alignment and projection for the volumetric additive manufacturing process. Each of the plurality of 2D images is an optimized image to print the 3D object at a respective rotational angle.