Using three-dimensional threshold matrices in the production of three-dimensional objects

• US 10,326,910 B2
• Filed: 04/28/2015
• Issued: 06/18/2019
• Est. Priority Date: 04/28/2015
• 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
• Primary Examiner(s): Rogers, Scott A
• Application Number:
  US15/544,796
• Publication Number:
  US 20180052447A1
• Time in Patent Office: 1,512 Days
• 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: B33Y 50/02 for controlling or regulating additive manufacturing processes
• 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

Certain examples described herein relate to the use of three-dimensional threshold matrices in the production of three-dimensional objects. In one case, data values for a three-dimensional matrix for use in halftoning are assigned based on a structural volume coverage representation. In certain described cases, the structural volume coverage representation defines a probabilistic distribution of at least two different structures available for the production of the three-dimensional object. A comparison is performed based on data values for the structural volume coverage representation. The output of the comparison is a data value to be assigned to the three-dimensional matrix. The resultant three-dimensional matrix is used in a halftoning operation to control a structure distribution in the three-dimensional object.

Claims

1. An apparatus to generate control data for production of a three-dimensional object comprising:

a halftone generator to apply a halftoning operation to data defining at least a portion of the three-dimensional object, the halftone generator being arranged to process the data defining at least the portion of the three-dimensional object in association with a three-dimensional threshold matrix to output discrete material formation instructions for at least one production material; and

a matrix generator to generate the three-dimensional threshold matrix for use by the halftone generator, the matrix generator being arranged to;

obtain a structural volume coverage representation defined with reference to at least one volume element corresponding to the three-dimensional object, the structural volume coverage representation comprising data values defining a probabilistic distribution of at least two different structures available for the production of the three-dimensional object;

compare at least one of said data values of the structural volume coverage representation to a predetermined blending threshold; and

assign a data value associated with one of the at least two structures to at least one corresponding volume element of the three-dimensional threshold matrix based on the comparison; and

a deposit mechanism, communicatively coupled to the halftone generator, to deposit available production materials according to the discrete material formation instructions output by the halftone generator.

2. The apparatus according to claim 1,

wherein the structural volume coverage representation comprises at least one structural volume coverage vector having at least two vector components corresponding to the at least two different structures, the structural volume coverage vector corresponding to at least a first volume element in a set of volume elements;

and

wherein the matrix generator is arranged to obtain data values for the at least two vector components based on a determined transition behavior among the at least two different structures for a position associated with the first volume element,

wherein said transition behavior is determined based on a transition function predefined between the positions of at least two further volume elements of the set of volume elements.

3. The apparatus according to claim 2, wherein the transition behavior is based on a determined distance metric between the position of the first volume element and the positions of the at least two further volume elements.

4. The apparatus according to claim 1, wherein the matrix generator is arranged to compare at least one of said data values of the structural volume coverage representation to at least one value in a predetermined blending threshold matrix.

5. The apparatus according to claim 4, wherein the predetermined blending threshold matrix is of the same dimensionality and size as halftone threshold matrices corresponding to each of the at least two different structures.

6. The apparatus according to claim 1,

wherein the data defining the three-dimensional object comprises at least one material volume coverage vector for at least one volume of the three-dimensional object,

wherein, for k materials available for production of the three-dimensional object and L discrete material formation states for said materials, the material coverage vector comprises Lk vector components, each vector component having an associated probability value,

wherein the halftone generator is arranged to perform a halftoning operation on the at least one material volume coverage vector, and

wherein the discrete material formation instructions comprise production instructions from a set of L*k available instruction values, each element at a production resolution having one of L material formation state instructions for each of said k materials.

7. A method for generating a three-dimensional halftone threshold matrix for use in production of a three-dimensional object, comprising:

obtaining a structural volume coverage representation for the three-dimensional object, the structural volume coverage representation comprising a structural volume coverage vector for at least one volume of the three-dimensional object, the structural volume coverage vector representing a proportional volumetric coverage of at least two different matrices; and

assigning a halftone threshold value to a corresponding volume of the three-dimensional halftone threshold matrix based on a comparison of the structure volume coverage vector with a predetermined blending threshold, the halftone threshold value corresponding to one of the at least two different matrices, wherein the three-dimensional halftone threshold matrix is applicable to an object definition for at least a portion of the three-dimensional object to instruct production of at least said portion of the three-dimensional object;

obtaining a digital representation for at least the portion of the three-dimensional object;

halftoning the digital representation using the three-dimensional halftone threshold matrix to generate control data for production of at least the portion of the three-dimensional object; and

producing at least the portion of the three-dimensional object on an additive manufacturing system using the generated control data.

8. The method according to claim 7, wherein obtaining a structural volume coverage representation comprises determining, for the at least one volume, a local transition behavior based on a predefined transition function,

wherein said transition function is predefined between the positions of at least two further volumes.

9. The method according to claim 7, wherein a structural volume coverage representation comprises determining, for the at least one volume, a set of barycentric coordinates relative to a set of at least two further volumes of the three-dimensional object.

10. The method of claim 7, wherein assigning a halftone threshold value to a corresponding volume of the three-dimensional halftone threshold comprises comparing the structure volume coverage vector associated with the at least one volume with a value in a predetermined transition threshold matrix corresponding to the at least one volume.

11. The method of claim 10, wherein the predetermined transition threshold matrix is of an equivalent size to each of the at least two independent structural matrices.

12. The method of claim 7,

wherein the digital representation comprises at least one material volume coverage vector for at least one volume of the three-dimensional object,

wherein, for k materials available for production of the three-dimensional object and L discrete material formation states for said materials, the material coverage vector comprises Lk vector components, each vector component having an associated probability value,

wherein halftoning is performed on the at least one material volume coverage vector, and

wherein the control data comprises discrete production instructions from a set of L*k available instruction values, each element at a production resolution having one of L material formation state instructions for each of said k materials.

13. A non-transitory machine readable medium comprising instructions relating to an electronic data structure for use in three-dimensional halftoning by a halftone generator, wherein the instructions are configured to:

define data values in association with a plurality of co-ordinates in three-dimensional space, the co-ordinates being defined according to a grid resolution in x, y and z dimensions, wherein the data values comprise threshold values for a three-dimensional halftone operation and are representative of a plurality of z-dimension planes arranged parallel to the x and y dimensions, and further wherein at least one data value comprises an indication of one of at least two different predefined spatial structures; and

determine said indication based on a probabilistic distribution of the at least two different predefined spatial structures obtained for the co-ordinates associated with said data value.