Mapping for three dimensional surfaces

Patent metadata

Field	Value
Publication number	US-9956717-B2
Application number	US-201414317244-A
Country	US
Kind code	B2
Filing date	Jun 27, 2014
Priority date	Jun 27, 2014
Publication date	May 1, 2018
Grant date	May 1, 2018

Abstract

The present disclosure includes a method for modifying an input image to map to a three dimensional shape prior to forming the three dimensional shape. The method includes receiving by a processor at least two pre-forming images of a locally unique non-repeating pattern printed on an input material. The at least two pre-forming images are captured prior to the input material being formed into the three dimensional shape. The method further includes receiving by the processor at least two post-forming images of the pattern printed on the input material, wherein the post-forming images are captured after the input material has been formed into the three dimensional shape and analyzing by the processor the at least pre-forming images and the at least two post-forming images to determine a translation table.

First claim

What is claimed is:

1. A method for modifying an input image to map to a three dimensional shape prior to forming the three dimensional shape comprising:
receiving by a processor data corresponding to a locally unique non-repeating pattern printed on an input material, wherein the data represents the pattern on the input material prior to the input material being formed into the three dimensional shape;
receiving by the processor at least two post-forming images of the pattern printed on the input material, wherein the post-forming images are captured after the input material has been formed into the three dimensional shape, such that each pixel of the pattern is positioned at a three dimensional location;
analyzing by the processor the locally unique pattern data and the at least two post-forming images to determine a translation table, wherein the translation table directly maps the three dimensional location of each pixel in the pattern on the three dimensional shape to a two dimensional location of each pixel in the pattern as printed on the input material;
reconstructing by the processor a three dimensional shape with color from a two-dimensional print using the translation table; and
forming by the processor a modified two dimensional print from the reconstructed three dimensional shape.

2. The method of claim 1 , wherein the data corresponding to the locally unique pattern comprises at least two pre-forming images of the input material with the pattern printed thereon prior to the input material being formed into the three dimensional shape.

3. The method of claim 2 , further comprises receiving the at least two-preforming images from a camera.

4. The method of claim 2 , wherein the pre-forming images and the post-forming images are captured from substantially the same locations.

5. The method of claim 1 , further comprising creating a modifying input image by using the translation table to modify the input image to map to the three dimensional shape.

6. The method of claim 1 , wherein the input material is substantially planar prior to being formed into the three dimensional shape.

7. The method of claim 1 , wherein each pixel in the pattern is uniquely identifiable.

8. A method for modifying a two-dimensional (2D) texture for a vacuum-formed three dimensional surface (3D) comprising:
receiving by a processor an image of a mapping pattern printed on an input material from at least two positions, the mapping pattern comprising a locally unique non-repeating pattern;
receiving by the processor a 2D image of a 3D surface of the input material from the at least two positions, wherein the 3D surface is created by deforming the input material;
determining by the processor a coordinate look-up table of the 3D surface corresponding to each pixel in the digital image of the mapping pattern from each of the at least two fixed positions, wherein the coordinate look-up table directly maps a 2D location of each pixel of the mapping pattern to a 3D location for each pixel of the mapping pattern;
reconstructing by the processor a 3D shape with color from a 2D print from a 2D texture coordinate look-up table; and
forming by the processor a modified 2D print from the reconstructed 3D shape.

9. The method of claim 8 , wherein the 2D texture coordinate look-up table comprises a displacement map.

10. The method of claim 8 , wherein forming a modified print comprises projecting the reconstructed 3D shape to the 2D plane of the 2D input surface, and receiving a 2D image of the 2D plane.

11. The method of claim 8 , wherein the non-repeating pattern comprises at least one of random color or random noise.

12. The method of claim 8 , wherein the non-repeating pattern allows each pixel within the pattern to be uniquely identified by a local neighborhood of surrounding pixels.

13. The method of claim 8 , wherein the non-repeating pattern is a pseudo random pattern.

14. The method of claim 8 , wherein the input material comprises a material selected from a group consisting of ABS, polystyrene, acrylic, polycarbonate, PVC, polyethylene, polypropylene, PETG, and a polymer blend.

15. The method of claim 8 , wherein the desired texture on the reconstructed 3D shape is accurate to 10 millimeters or less to a desired texture.

16. A system for modifying an input image to print on a material before the material is formed to a three-dimensional shape comprising:
a light source configured to light a surface of the material; one or more cameras configured to capture an image of a locally unique, non-repeating pattern printed on the material from at least two positions relative to the material;
a computer in communication with the camera comprising a processor configured to perform the following operations:
determining a 2D texture coordinate look-up table of a vacuum-formed 3D surface based, at least in part, on distortions in the locally unique, non-repeating pattern, wherein the 2D texture coordinate look-up table directly translates a 2D location of a select pixel in the pattern to a 3D location of the selected pixel on the 3D surface; and
a printer in communication with the computer, wherein the printer prints a distorted 2D texture on a thermoforming material based on the 2D texture coordinate look-up table.

17. The system of claim 16 , wherein the 3D surface is vacuum-formed from a planar thermoforming material.

18. The system of claim 17 , wherein the planar thermoforming material comprises a 2D texture.

19. The system of claim 16 , further comprising a projector to project images onto a projection surface, wherein the projector is in communication with the computer.

20. A method for producing a 3D surface with a distorted 2D texture, the method comprising:
generating a modified 2D texture from an un-deformed 2D input texture according to a 2D texture coordinate look-up table for a vacuum formed 3D surface, wherein the 2D texture coordinate look-up table is formed by analyzing images of a locally unique non-repeating pattern printed on a sample thermoforming material and translates a pixel location for pixels in the pattern between a 2D location on the un-deformed 2D input texture to a 3D location on the formed 3D surface;
printing the distorted 2D texture on a thermoforming material; and
vacuum forming the thermoforming material into the 3D surface with a desired texture.

21. The method of claim 20 , the step of printing comprising spraying ink on the thermoforming material.

22. The method of claim 20 , wherein the desired texture on the 3D surface is accurate to 10 millimeter or less.

23. The method of claim 20 , the step of generating a distorted 2D texture comprising:
capturing a digital image of a 2D input surface from at least two fixed positions;
printing a two-dimensional (2D) texture from one of the digital images on a planar thermoforming material, each pixel of the 2D texture comprises a unique element of the locally unique non-repeating pattern;
deforming the thermoforming material to form a three-dimensional (3D) surface;
capturing a 2D image of the 3D surface from at least two fixed positions; and
determining a 2D texture coordinate look-up table of the 3D surface corresponding to each pixel in the digital image of the 2D input surface from each of the at least two fixed positions.

24. The method of claim 21 , further comprising obtaining a 3D scan of the vacuum-formed 3D surface; and aligning the 3D scan with a 3D scan with p

Assignees

• Disney Entpr Inc

Inventors

• Grundhofer Anselm
• Laduke Thomas F
• Rose David Robert Wyatt
• Zimmer Henning
• Comploi Dumene

Classifications

• B29C51/10

  Forming by pressure difference, e.g. vacuum · CPC title

• B29C51/264 Primary

  Auxiliary operations prior to the thermoforming operation, e.g. cutting (B29C51/42, B29C51/46 take precedence) · CPC title

• B29C51/46 Primary

  Measuring, controlling or regulating · CPC title

• B29C51/08

  Deep drawing or matched-mould forming, i.e. using mechanical means only · CPC title

• B29C2795/002

  before shaping · CPC title