3D printing with custom surface reflectance

• US 9,827,719 B2
• Filed: 11/19/2015
• Issued: 11/28/2017
• 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, Roullier, Olivier, Bickel, Bernd, Alexa, Marc, Matusik, Wojciech
• Primary Examiner(s): Masinick, Michael D
• Application Number:
  US14/945,595
• Publication Number:
  US 20160075090A1
• Time in Patent Office: 740 Days
• 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 3D printing method, comprising:

providing a diffuse base layer;

printing a layer of transparent material comprising a surface with a plurality of micro-structures, wherein the micro-structures are configured based on a 3D model defining a geometry corresponding to a numerical representation of a target reflectance; and

forming a 3D printed object by attaching the layer of transparent material to the diffuse base layer with the micro-structures facing away from the diffuse base layer to define reflectance for the 3D printed object.

2. The method of claim 1, wherein the providing, the printing, and the forming are performed by a single multi-material 3D printer.

3. The method of claim 1, further comprising measuring reflectances of printing materials available for the diffuse base layer and the layer of transparent material and, based on the measured reflectances, optimizing the geometry of the micro-structures to reproduce the numerical representation.

4. The method of claim 1, wherein the numerical representation comprises a normal distribution function (NDF).

5. The method of claim 4, wherein the geometry of each of the micro-structures is provided by performing a Voronoi optimization.

6. The method of claim 5, wherein each of the micro-structures comprises a base with one or more sidewalls extending outward from the base and wherein outer surfaces of the one or more sidewalls comprises a plurality of facets.

7. The method of claim 6, wherein the facets each have substantially equal areas.

8. The method of claim 6, wherein the base is circular or oval in shape, whereby the body is dome shaped.

9. A 3D printing method, comprising:

providing a diffuse base layer;

printing a layer of transparent material comprising a surface with a plurality of micro-structures, wherein the micro-structures are configured based on a 3D model defining a geometry corresponding to a numerical representation of a target reflectance;

forming a 3D printed object by attaching the layer of transparent material to the diffuse base layer with the micro-structures facing away from the diffuse base layer to define reflectance for the 3D printed object, wherein the providing, the printing, and the forming are performed by a single multi-material 3D printer;

measuring reflectances of printing materials available for the diffuse base layer and the layer of transparent material; and

based on the measured reflectances, optimizing the geometry of the micro-structures to reproduce the numerical representation.

10. The method of claim 9, wherein the numerical representation comprises a normal distribution function (NDF) and wherein the geometry of each of the micro-structures is provided by performing a Voronoi optimization.

11. The method of claim 10, wherein each of the micro-structures comprises a base with one or more sidewalls extending outward from the base and wherein outer surfaces of the one or more sidewalls comprises a plurality of facets, wherein the facets each have substantially equal areas, and wherein the base is circular or oval in shape, whereby the body is dome shaped.