Three-dimensional halftoning by selecting submatrix of halftone matrix to halftone each slice or layer of object

• US 10,306,106 B2
• Filed: 10/29/2014
• Issued: 05/28/2019
• Est. Priority Date: 10/29/2014
• Status: Active Grant

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Morovic, Peter, Morovic, Jan, Gondek, Jay S.
• Primary Examiner(s): Rogers, Scott A
• Application Number:
  US15/520,307
• Publication Number:
  US 20170318186A1
• Time in Patent Office: 1,672 Days
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: H04N 1/405 Halftoning, i.e. converting the picture signal of a continuous-tone original into a corresponding signal showing only two levels

Abstract

A three-dimensional halftoning method is disclosed, wherein a halftone matrix including values is provided and subdivided into a plurality of sub-matrices, each sub-matrix including values of the halftone matrix in a respective sub-range. For a current slice of a three-dimensional representation of an object, a sub-matrix of the plurality of sub-matrices of the halftone matrix is selected and halftoning of the current slice is performed using the selected sub-matrix. Furthermore, an additive manufacturing method and system are described.

Claims

1. A three-dimensional halftoning method, comprising:

providing a halftone matrix including values;

subdividing the halftone matrix into a plurality of sub-matrices, each sub-matrix including values of the halftone matrix in a respective sub-range;

selecting, for a current slice of a three-dimensional representation of an object, a sub-matrix of the plurality of sub-matrices of the halftone matrix;

halftoning the current slice using the selected sub-matrix; and

depositing material on a layer of the object according to said halftoning of the corresponding slice.

2. The method according to claim 1, further comprising selecting, for a subsequent slice of the three-dimensional model of the object, a subsequent sub-matrix of the plurality of sub-matrices of the halftone matrix, and halftoning the subsequent slice using the subsequent sub-matrix.

3. The method according to claim 1, further comprising sequentially arranging the plurality of sub-matrices according to the sub-ranges.

4. The method according to claim 1, wherein said selecting the sub-matrix for the current slice or the subsequent slice includes selecting the sub-matrix based on a number of the current slice or subsequent slice modulo a total number of the sub-matrices.

5. The method according to claim 1, further comprising partitioning a range of the values of the halftone matrix into a plurality of equal and disjoint sub-ranges.

6. The method according to claim 1, further comprising determining current processing parameters and optimizing the halftone matrix based on the current processing parameters.

7. The method according to claim 1, wherein said representation of the object includes a plurality of values for elements of the object on each slice and said halftoning includes thresholding the values of the representation using corresponding values of the respective sub-matrix, wherein said plurality of values correspond to a plurality of area coverage vectors defined for respective elements of the object.

8. The method according to claim 1, wherein each element of the representation of the object corresponds to a region of sub-elements to be printed on a layer.

9. The method according to claim 1, wherein the sub-ranges are overlapping sub-ranges according to an overlap value.

10. An additive manufacturing method for producing an object from a digital representation of the object, said method comprising:

determining area coverage vectors for each pixel on each slice of the digital representation of the object;

subdividing a two-dimensional halftone matrix including threshold values into a plurality of sequentially arranged sub-matrices, each sub-matrix including threshold values of the halftone matrix in a respective sub-range;

for each layer of a sequential manufacturing sequence;

determining a slice of the digital representation of the object corresponding to the layer;

selecting a sub-matrix of the plurality of sequentially arranged sub-matrices based on a number of the slice modulo a total number of the sequentially arranged sub-matrices,

halftoning the area coverage vectors for the slice using respective threshold values of the selected sub-matrix, and

depositing material or fluid on the layer according to results of said halftoning of the area coverage vectors for the slice.

11. The method according to claim 10, wherein said depositing material includes depositing a build material or printing fluid.

12. The method according to claim 10, wherein said two-dimensional halftone matrix is a void-and-cluster matrix.

13. An additive manufacturing system, comprising:

a print head to deposit successive layers of material or fluid; and

a processor operatively coupled to the print head so as to control deposition of the successive layers of material or fluid, wherein, for an object to be manufactured, the processor is to;

provide a halftone matrix including values,

subdivide the halftone matrix into a plurality of sub-matrices, each sub-matrix including values of the halftone matrix in a respective sub-range,

select, for a current layer to be manufactured, a sub-matrix of the plurality of sub-matrices of the halftone matrix, and

halftone a representation of the object for the current layer using the selected sub-matrix,

wherein the processor is to control deposition of material or fluid for the current layer according to results of the halftoning.

14. The printing system according to claim 13, further comprising a chamber for holding a bed of powdered base material, wherein the print head distributes successive layers of powder in said chamber and selectively ejects binder and differently colored inks into each layer of powder based on results of the halftoning for the respective layer.