3D printing using DLP technology
Photocurable molding (SLA), a common 3D printing process, is very similar to conventional printing. Similar to a toner cartridge that deposits toner on paper, a 3D printer deposits several layers of material on successive 2D cross-sections. These materials are stacked one on top of the other to produce an actual 3D object. When using SLA, this material is a resin cured with an ultraviolet (UV) light source. As the resin solidifies, its monomer crosslinks to create a polymer chain that produces a solid material.
When the SLA is used in combination with a DLP chipset, a UV light source is used to illuminate the DMD. Then, the pixels of the DMD are used to generate a pattern of the image, and this image is projected on the resin layer to produce a continuous cross-section, constituting a 3D object. The advantage of using DLP technology is that, in addition to imaging the light source directly on the resin, optical elements are also used to image individual pixels from the DMD, which optimizes resolution and feature size.
Compared to conventional laser-based SLA machines capable of producing 100 μm voxels (3D pixels), SLA machines that provide auxiliary functions by DLP technology are able to achieve voxels with a minimum of 30 μm. Smaller voxels translate directly into smoother objects, which means fewer subsequent processing is required to complete the goal. In addition, because imaging and production of the entire structural layer are performed simultaneously, rather than each voxel, each layer is completed, these machines are faster than traditional SLA machines in making large prints.
DLP technology measurement and test
Traditional machine vision systems use a contact-based coordinate measurement method to scan an object or a non-contact 2D detection and measurement method using a single camera. A 3D machine vision assisted with DLP technology uses a method called structured light, which is a variant of single-line scanning. The digital light pattern is projected onto an object and is imaged by a camera sensor; this sensor triangulates the data with a known light source angle to extract the 3D data.
The DMD turns the corresponding column of pixels on or off, in this way producing a projected pattern, usually black and white bars. By using a projection lens, light from the DMD is imaged on the object being measured. Since the size of the DMD pixel can be only 5.4 [mu]m, a small panel can be used to create the pattern.
Compared to traditional single-line scans and contact-based coordinate measurements, structured light methods assisted with DLP technology can generate high-precision 3D data in real time, due to its high resolution capabilities and fast, programmable graphics rates up to 32 kHz. In addition, DMDs allow for a great deal of flexibility in system design, allowing a wide variety of wavelengths to be selected from 365 nm to 2500 nm.
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