3D printing with custom surface reflectance

• US 9,266,287 B2
• Filed: 09/18/2013
• Issued: 02/23/2016
• Est. Priority Date: 09/18/2013
• Status: Active Grant

• Current Assignee: Disney Enterprises Incorporated (The Walt Disney Company)
• Original Assignee: Disney Enterprises Incorporated (The Walt Disney Company)
• Inventors: Kautz, Jan, Bickel, Bernd, Alexa, Marc, Matusik, Wojciech, Roullier, Olivier
• Primary Examiner(s): Masinick, Michael D
• Application Number:
  US14/030,176
• Publication Number:
  US 20150079327A1
• Time in Patent Office: 888 Days
• Field of Search: 700/98
• US Class Current: 1/1
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2995/0026 Transparent
• CPC Class Codes: B29K 2995/003 Reflective
• CPC Class Codes: B29L 2031/773 Dome-shaped igloos B29L2031/106, frameless domes B29L2025/00
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 428/21 Circular sheet or circular blank
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Abstract

A method for fabricating custom surface reflectance and spatially-varying bi-directional reflectance distribution functions (BDRFs or svBRDFs). The 3D printing method optimizes micro-geometry to produce a normal distribution function (NDF) that can be printed on surfaces with a 3D printer. Particularly, the method involves optimizing the micro-geometry for a wide range of analytic NDFs and simulating the effective reflectance of the resulting surface. Using the results of the simulation, the appearance of an input svBRDF can be reproduced. To this end, the micro-geometry is optimized in a data-driven fashion and distributed on the surface of the printed object. The methods were demonstrated to allow 3D printing svBRDF on planar samples with current 3D printing technology even with a limited set of printing materials, and the described methods have been shown to be naturally extendable to printing svBRDF on arbitrary shapes or 3D objects.

Claims

1. A method for use in 3D printing an object with customizable reflectances, comprising:

for a set of printing materials for a 3D printer, determining a bidirectional reflectance distribution function (BRDF) for a base diffuse layer and for a specular outer layer;

with a set of normal distribution functions (NDFs), computing a corresponding geometry for a multi-faceted micro-structure;

measuring reflectances of the specular outer layer with a surface of the specular outer layer comprising a plurality of the multi-faceted micro-structures corresponding to each of the NDFs with the set of printing materials;

simulating a resulting BRDF of the base diffuse layer covered with the specular outer layer with the multi-faceted micro-structures;

with an input target reflectance, determining a geometry of the multi-faceted micro-structures and a density on the surface of the specular outer layer to synthesize one of the NDFs; and

operating a 3D printer to print a 3D object using the determined geometry and the set of printer materials.

2. The method of claim 1, wherein the determining the geometry comprises performing Voronoi optimization of to define facets of the micro-structures.

3. The method of claim 1, further comprising with an additional input target reflectance, determining an additional geometry of the multi-faceted micro-structures to synthesize another one of the NDFs and wherein the operating of the 3D printer comprises printing the 3D object using the determined geometry, whereby the printed 3D object has two or more reflectances.