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A Continuous Motion Shape-from-Focus Method for Geometry Measurement during 3D Printing.

Jona Gladines1, Seppe Sels1, Michael Hillen1

  • 1Faculty of Applied Engineering, University of Antwerp, 2020 Antwerp, Belgium.

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Summary

This study introduces a new shape-from-focus method for 3D printing quality control. It enables accurate 3D measurements during continuous scanning, reducing waste in additive manufacturing.

Keywords:
focus variationlaser triangulationoptical dimensional metrologyshape measurementshape-from-focustopography

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Area of Science:

  • Additive Manufacturing
  • Metrology
  • Computer Vision

Background:

  • Zero-defect manufacturing is crucial in 3D printing to minimize waste.
  • Accurate in-process 3D measurement is needed for real-time quality evaluation and process adjustment.
  • Traditional shape-from-focus methods require stationary objects, incompatible with dynamic 3D printing.

Purpose of the Study:

  • To develop a novel shape-from-focus methodology adaptable to continuous scanning motions.
  • To enable in-process 3D shape recovery for real-time quality control in additive manufacturing.
  • To assess the feasibility and accuracy of the proposed method for 3D printing applications.

Main Methods:

  • Developed a synchronized system controlling a camera trigger and a tunable lens for image acquisition during motion.
  • Implemented image re-alignment techniques to reconstruct 3D depth information from a dynamic image stack.
  • Analytically compared measurement accuracy against a stationary shape-from-focus method and a known reference.

Main Results:

  • The proposed method successfully enables shape-from-focus measurements during continuous scanning.
  • A slight degradation of 1.22% in measurement error was observed compared to the stationary method.
  • The methodology is suitable for integration into the 3D printing process for in-line quality assessment.

Conclusions:

  • The novel methodology allows shape-from-focus to be applied to the dynamic environment of 3D printing.
  • This advancement supports the goal of zero-defect manufacturing by enabling early detection of nonconformities.
  • The research paves the way for real-time, in-process metrology in additive manufacturing.