Edge smoothness with low resolution projected images for use in solid imaging
First Claim
1. A method for forming a three-dimensional object layer-by-layer comprising the steps of:
- a. receiving three-dimensional CAD data of an object to be built;
b. processing the three-dimensional CAD data to receive slice data representative of cross-sectional layers of the object;
c. converting the slice data into bit-map data;
d. delivering a photocurable solidifiable liquid medium to an imaging area via a radiation transparent carrier;
e. projecting an image representative of cross-sectional image data from a radiation source through the radiation transparent carrier to selectively illuminate pixels in an image plane in a first exposure to selectively solidify the liquid medium;
f. displacing the cross-sectional image data by a subpixel amount; and
g. projecting an image representative of the displaced cross-sectional image to selectively illuminate pixels in the image plane in the second exposure to selectively solidify the liquid medium.
3 Assignments
0 Petitions
Accused Products
Abstract
A solid imaging apparatus and method employing sub-pixel shifting in multiple exposures of the digitally light projected image of a cross-section of a three-dimensional object on a solidifiable liquid medium. The multiple exposures provide increased resolution, preserving image features in a three-dimensional object and smoothing out rough or uneven edges that would otherwise be occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Algorithms are used to select pixels to be illuminated within the boundary of each image projected in the cross-section being exposed.
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Citations
64 Claims
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1. A method for forming a three-dimensional object layer-by-layer comprising the steps of:
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a. receiving three-dimensional CAD data of an object to be built;
b. processing the three-dimensional CAD data to receive slice data representative of cross-sectional layers of the object;
c. converting the slice data into bit-map data;
d. delivering a photocurable solidifiable liquid medium to an imaging area via a radiation transparent carrier;
e. projecting an image representative of cross-sectional image data from a radiation source through the radiation transparent carrier to selectively illuminate pixels in an image plane in a first exposure to selectively solidify the liquid medium;
f. displacing the cross-sectional image data by a subpixel amount; and
g. projecting an image representative of the displaced cross-sectional image to selectively illuminate pixels in the image plane in the second exposure to selectively solidify the liquid medium. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 63)
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15. In an apparatus for forming a three-dimensional object layer-by-layer by solid imaging comprising in combination:
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a. a frame;
b. transparent transport means moveably mounted to the frame;
c. a radiation source mounted to the frame for projecting a full image one cross-section at a time of a three-dimensional object to be built through the transparent transport means;
d. a source of solidifiable liquid medium in fluid flow communication with the transparent transport means effective to apply the solidifiable liquid medium to the transparent transport means;
e. a support platform moveably mounted to the frame to support the three-dimensional object as it is built layer-by-layer;
f. control means mounted to the frame effective to control movement of the transparent transport means and the support platform and to control illumination of selected pixels by the radiation source in an image exposure of a cross-section of the three-dimensional object on the solidifiable liquid medium;
g. processing means in data flow communication with the control means to receive CAD data and convert the CAD data into sliced data representative of cross-sections of the three-dimensional object; and
h. a supixel image placement device connected to the frame effective to move a projected image of the three-dimensional object in at least one additional exposure of a previously exposed cross-section of the three-dimensional image to obtain a high resolution image and a three-dimensional object that has all features properly positioned and smooth edges. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 43, 44, 45, 46, 47, 48)
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33. In an apparatus for forming a three-dimensional object layer-by-layer by solid imaging comprising in combination:
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a. a frame;
b. a source of solidifiable liquid medium effective to supply the solidifiable liquid medium to form a layer of medium to be solidified with an exposed surface;
c. a radiation source mounted to the frame for projecting onto the surface of the liquid medium a cross-section at a time of a three-dimensional object to be built effective to solidify each cross-section of the three-dimensional object;
d. a support platform moveably mounted to the frame to support the three-dimensional object as it is built layer-by-layer;
e. control means mounted to the frame effective to control recoating of an exposed layer of the liquid medium with a fresh layer of the solidifiable liquid medium, movement of the support platform, and to control illumination of selected pixels by the radiation source in an image exposure of a cross-section of the three-dimensional object on the solidifiable liquid medium;
f. processing means in data flow communication with die control means to receive three-dimensional CAD data and convert the CAD data into sliced data representative of cross-sections of the three-dimensional object; and
g. a sub-pixel image placement device connected to the frame effective to move a projected image of the three-dimensional object in at least one additional exposure of a previously exposed cross-section of the three-dimensional image to obtain a high resolution image and a three-dimensional object that bas all features properly positioned and smooth edges. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41, 42)
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49. A method for forming a three-dimensional object layer-by-layer comprising the steps of:
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a. receiving three-dimensional CAD data of an object to be built;
b. processing the three-dimensional CAD data to receive slice data representative of cross-sectional layers of the object;
c. converting the slice data into bit-map data;
d. delivering a photocurable solidifiable liquid medium to an imaging area;
e. projecting an image representative of cross-sectional image data from a radiation source onto the photocurable solidifiable liquid in the imaging area to selectively illuminate pixels in an image plane in a first exposure to selectively solidify the liquid medium;
f. displacing the cross-sectional image data by a sub-pixel amount; and
g. projecting an image representative of the displaced cross-sectional image to selectively illuminate pixels onto the photocurable solidifiable liquid in the image plane in a second exposure to selectively solidify the liquid medium;
- View Dependent Claims (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 64)
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Specification