Additive manufacturing , also known as 3D printing , and 3D machine vision are exciting new technologies. When we combine the two, they have the potential to create some new and efficient production models, especially Interested in the concept of “automated production†– a “one-stop†machining shop that uses 3D printing technology to create parts without manual supervision and machine vision technology for measurement and testing. The part.
Texas Instruments' DLP technology and its core digital micromirror device (DMD) provide the key to achieving this. DLP technology is an optical technology for projection display that was born in 1996 and is now widely used. When applied to problems in 3D printing and machine vision, DLP technology delivers high-resolution imaging, speeds up production and lowers manufacturing costs, helping to make the vision of automated production a reality. Because of this, it has become a classic example of using old technology to solve new problems.
3D printing with DLP technology
Light curing (SLA) is a common 3D printing process that is similar to traditional printing. Just as toner is deposited on paper, a 3D printer can deposit a layer of material in a series of 2D sections so that layers are stacked to create a 3D object. In the case of SLA technology, the material is a resin that can be cured by an ultraviolet (UV) light source. When the resin cures, its monomers can crosslink to create a polymer chain that can produce a solid material.
When SLA technology is combined with DLP technology, the DMD is illuminated by a UV light source. The pixels of the DMD are then processed separately and the image is projected onto the resin layer, resulting in a series of sections that can form a 3D object. The use of DLP technology offers a number of advantages, such as the ability to image individual pixels from a DMD using optical technology, rather than allowing the source to be imaged directly onto the resin, which optimizes resolution and feature size.
Light curing using DLP technology
Photocuring with DLP technology: Objects are detailed in 3D Computer Aided Design (CAD) models. The printer software converts the virtual model into a series of skins to accommodate the printing of the object. (provided by Texas Instruments)
Compared to traditional laser-based SLA machines that produce 100 micron voxel (3D pixels), DLP-based SLA machines can achieve 30 micron voxels. The smaller the voxel, the smoother the object is transformed, which means less post-production processing is required to complete the object creation. In addition, because the imaging and creation of the entire structural layer is done simultaneously—rather than one voxel, layer by layer, these machines complete larger prints faster than traditional SLA machines.
DLP technology measurement and testing
After the object is printed, the next step on the automated production line is to implement a machine with 3D vision that automatically measures and tests the object. DLP technology can also be applied in this process.
Traditional machine vision systems use contact coordinate measurement or non-contact 2D detection and measurement using a single camera to scan an object. DLP-assisted 3D machine vision systems can use the one-line scanning variant method - structured light method. Here, the digital light pattern is projected onto an object. These light patterns are then imaged by a camera sensor that can triangulate the data with known light source angles to extract 3D information.
The above figure is a structural light scanning method using DLP technology, which can extract the dimensional values ​​of surface area, volume and feature size of any object. (provided by Texas Instruments)
The projected pattern is typically black and white stripes that are created by the DMD turning the corresponding pixel columns on and off. We use a projection lens to image light from the DMD on the object being measured. Since the size of the DMD pixels may be only 5.4 microns, we can use smaller panels to create high resolution patterns.
DLP-assisted 3D machine vision system
DLP-assisted 3D machine vision system: DLP technology enables 3D machine vision by providing 3D image capture for single or multiple cameras. The system can use a DMD as a spatial light modulator and a DMD controller to provide high-speed control of the micromirrors. (provided by Texas Instruments)
Compared to traditional single-row scanning and contact coordinate measurement, DLP-assisted structured light methods have high resolution and programmable pattern rates of up to 32 kHz, resulting in highly accurate 3D real-time data. In addition, DMD offers flexibility in system design – with a wide range of wavelengths from 365 nm to 2,500 nm.
The need to improve product quality and reduce manufacturing costs is becoming more robust in a range of areas, including safety, healthcare, environment and science. With TI's DLP technology, engineers have a way to meet these needs and can imagine an ideal manufacturing plant where automated robots can manufacture and test products.
Alex Lyubarsky is an optical design engineer at Texas Instruments.
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