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

In 3D printing, as in other manufacturing processes, there is a push for zero-defect manufacturing, mainly to avoid waste. To evaluate the quality of the printed parts during the printing process, an accurate 3D measurement method is required. By scanning the part during the buildup, potential nonconformities to tolerances can be detected early on and the printing process could be adjusted to avoid scrapping the part. Out of many, shape-from-focus, is an accurate method for recovering 3D shapes from objects. However, the state-of-the-art implementation of the method requires the object to be stationary during a measurement. This does not reconcile with the nature of 3D printing, where continuous motion is required for the manufacturing process. This research presents a novel methodology that allows shape-from-focus to be used in a continuous scanning motion, thus making it possible to apply it to the 3D manufacturing process. By controlling the camera trigger and a tunable lens with synchronous signals, a stack of images can be created while the camera or the object is in motion. These images can be re-aligned and then used to create a 3D depth image. The impact on the quality of the 3D measurement was tested by analytically comparing the quality of a scan using the traditional stationary method and of the proposed method to a known reference. The results demonstrate a 1.22% degradation in the measurement error.