Additive manufacturing based on optimized mask video projection for improved accuracy and resolution

Additive manufacturing (AM) processes based on mask image projection such as digital micro-mirror devices (DMD) have the potential to be fast and inexpensive. More and more research and commercial systems have been developed based on such digital devices. However, the accuracy and resolution of the related AM processes are constrained by the limited number of mirrors in a DMD. In this paper, a novel AM process based on the mask video projection has been presented. For each layer, a set of mask images instead of a single image are planned based on the principle of the optimized pixel blending. The planned images are then projected in synchronization with the small movement of the building platform. A mask image planning method has been presented for the formulated optimization problem. Experimental results have verified that the mask video projection process can significantly improve the accuracy and resolution of built components.