Sub-pixel grayscale three-dimensional printing

Patent metadata

Field	Value
Publication number	US-2017102679-A1
Application number	US-201615287205-A
Country	US
Kind code	A1
Filing date	Oct 6, 2016
Priority date	Oct 7, 2015
Publication date	Apr 13, 2017
Grant date	—

Abstract

Techniques and systems for sub-pixel grayscale three-dimensional (3D) printing are described. A technique includes mapping a 3D digital model onto a 3D grid of voxels associated with a 3D printer; assigning a first intensity level to first voxels that are fully contained within the model, the first intensity level being sufficient to cure photoactive resin during a curing time; determining, based on geometric information provided by the model, containment degrees for second voxels that are partially contained within the model; assigning second intensity levels to the second voxels based respectively on the containment degrees, the second intensity levels being greater than a third intensity level and lesser than the first intensity level; assigning the third intensity level to third voxels that are outside of the model; and generating one or more graphic files based on the first, second, third voxels, and respectively assigned intensity levels.

First claim

What is claimed is:

1 . A method comprising:
obtaining, by a data processing apparatus, a digital model that describes a three-dimensional structure; mapping, by the data processing apparatus, the digital model onto a three-dimensional grid of voxels associated with a three-dimensional printer; assigning, by the data processing apparatus, a first intensity level to one or more first voxels of the grid of voxels that are fully contained within the digital model, wherein the first intensity level is sufficient to cure photoactive resin during a predetermined curing time associated with the three-dimensional printer; determining, by the data processing apparatus based on geometric information provided by the digital model, one or more containment degrees for one or more second voxels of the grid of voxels that are partially contained within the digital model; assigning, by the data processing apparatus, one or more second intensity levels to the one or more second voxels based respectively on the one or more containment degrees, the one or more second intensity levels being greater than a third intensity level and lesser than the first intensity level, assigning, by the data processing apparatus, the third intensity level to one or more third voxels of the grid of voxels that are outside of the digital model; and generating, by the data processing apparatus, one or more graphic files based on the one or more first voxels, the one or more second voxels, the one or more third voxels, and the assigned intensity levels.

2 . The method of claim 1 , comprising:
sending the one or more graphic files to the three-dimensional printer.

3 . The method of claim 1 , wherein determining the one or more containment degrees comprises:
determining a number of first points within a voxel that are at least partially contained by the digital model; determining a number of second points within the voxel that are not contained by the digital model; and determining a containment degree of the voxel based on the number of first points and the number of second points.

4 . The method of claim 1 , wherein determining the one or more containment degrees comprises:
determining a covered volume within a voxel that is contained by the digital model; and determining a containment degree of the voxel based on the covered volume and a total volume of the voxel.

5 . The method of claim 1 , wherein mapping the digital model onto the three-dimensional grid of voxels comprises slicing the digital model into two-dimensional slices and mapping each slice onto a two-dimensional grid of pixels.

6 . The method of claim 1 , wherein the one or more second voxels of the grid of voxels are sliced to form one or more pixels, wherein determining the one or more containment degrees comprises:
determining a number of first points within a pixel of the one or more pixels that are at least partially contained by the digital model; determining a number of second points within the pixel that are not contained by the digital model; and determining a containment degree of the pixel based on the number of first points and the number of second points.

7 . The method of claim 1 , comprising:
adjusting the one or more second intensity levels based on a nonlinear characteristic of the photoactive resin.

8 . The method of claim 1 , comprising:
adjusting the one or more second intensity levels based on a nonlinear characteristic of a light source within the three dimensional printer.

9 . The method of claim 1 , comprising:
scaling the digital model based on a scaling factor, wherein mapping the digital model comprises slicing the scaled digital model, and wherein the one or more containment degrees are based on combinations of groups of pixels from slices of the scaled digital model.

10 . A system comprising:
a processor; and a memory structure coupled with the processor, the memory structure configured to store a digital model that describes a three-dimensional structure, wherein the processor is configured to perform operations comprising:
mapping the digital model onto a three-dimensional grid of voxels associated with a three-dimensional printer;
assigning a first intensity level to one or more first voxels of the grid of voxels that are fully contained within the digital model, wherein the first intensity level is sufficient to cure photoactive resin during a predetermined curing time associated with the three-dimensional printer;
determining, based on geometric information provided by the digital model, one or more containment degrees for one or more second voxels of the grid of voxels that are partially contained within the digital model;
assigning one or more second intensity levels to the one or more second voxels based respectively on the one or more containment degrees, the one or more second intensity levels being greater than a third intensity level and lesser than the first intensity level; and
generating one or more graphic files based on the one or more first voxels, the one or more second voxels, and the assigned intensity levels.

11 . The system of claim 10 , wherein the operations comprise:
sending the one or more graphic files to the three-dimensional printer.

12 . The system of claim 10 , wherein determining the one or more containment degrees comprises:
determining a number of first points within a voxel that are at least partially contained by the digital model; determining a number of second points within the voxel that are not contained by the digital model; and determining a containment degree of the voxel based on the number of first points and the number of second points.

13 . The system of claim 10 , wherein determining the one or more containment degrees comprises:
determining a covered volume within a voxel that is contained by the digital model; and determining a containment degree of the voxel based on the covered volume and a total volume of the voxel.

14 . The system of claim 10 , wherein mapping the digital model onto the three-dimensional grid of voxels comprises slicing the digital model into two-dimensional slices and mapping each slice onto a two-dimensional grid of pixels.

15 . The system of claim 10 , wherein the one or more second voxels of the grid of voxels are sliced to form one or more pixels, wherein determining the one or more containment degrees comprises:
determining a number of first points within a pixel of the one or more pixels that are at least partially contained by the digital model; determining a number of second points within the pixel that are not contained by the digital model; and determining a containment degree of the pixel based on the number of first points and the number of second points.

16 . The system of claim 10 , wherein the operations comprise:
adjusting the one or more second intensity levels based on a nonlinear characteristic of the photoactive resin.

17 . The system of claim 10 , wherein the operations comprise:
adjusting the one or more second intensity levels based on a nonlinear characteristic of a light source within the three dimensional printer.

18 . The system of claim 10 , wherein the operations comprise:
scaling the digital model based on a scaling factor, wherein mapping the digital model comprises slicing the scaled digital model, and wherein the one or more containment degrees are based on combinations of groups of pixels from slices of the scaled digital model.

19 . The system of claim 10 , wherein the operatio

Assignees

• Autodesk Inc

Inventors

• Greene Richard M
• Schmidt Ryan Michael

Classifications

• B29C64/129 Primary

  characterised by the energy source therefor, e.g. by global irradiation combined with a mask · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• H04N1/6061

  involving the consideration or construction of a gamut surface · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C64/386 Primary

  Data acquisition or data processing for additive manufacturing · CPC title