Optical three dimensional scanners and methods of use thereof

Abstract

An optical scanner includes a light source located within a housing. A reticle having an aperture is positioned within the housing to receive a first light beam emitted from the light source. The reticle is configured to transmit a second light beam through the aperture. A mirror is positioned within the housing to receive the second light beam transmitted from the reticle and reflect the second light beam through a first window in the housing onto a surface of interest of an object. A light receiver is configured to receive a third light beam from the surface of interest of the object through a second window in the housing, wherein the light receiver is configured to obtain one or more light position values to determine a parameter of the surface of interest of the object. Methods for generating three-dimensional images of an object utilizing the optical scanner are also disclosed.

What is claimed is: 
     
         1 . An optical scanner comprising:
 a light source located within a housing;   an opaque reticle having an aperture, the reticle positioned within the housing to receive a first light beam emitted from the light source and configured to transmit a second light beam through the aperture, wherein the aperture forms a transmissive pattern for the second light beam;   a mirror positioned within the housing to receive the second light beam transmitted from the reticle and reflect the second light beam through a first window in the housing onto a surface of interest of an object, wherein the mirror is configured to rotate to scan the second light beam along at least one axis of the object; and   a light receiver configured to receive a third light beam from the surface of interest of the object through a second window in the housing, wherein the light receiver is configured to obtain one or more light position values to determine a parameter of the surface of interest of the object.   
     
     
         2 . The optical scanner as set forth in  claim 1 , wherein the light source is a light emitting diode, a semiconductor laser, or a pulsed laser source. 
     
     
         3 . The optical scanner as set forth in  claim 1 , wherein the light source has a wavelength of less than 500 nm. 
     
     
         4 . The optical scanner as set forth in  claim 1 , wherein the light receiver further comprises an imaging lens. 
     
     
         5 . The optical scanner as set forth in  claim 4 , wherein the imaging lens is telecentric in object space. 
     
     
         6 . The optical scanner as set forth in  claim 4  further comprising:
 an optical filter configured to transmit substantially only light of a wavelength emitted by the light source. 
 
     
     
         7 . The optical scanner as set forth in  claim 4 , wherein the imaging lens is positioned within the housing with an axis of the imaging lens substantially perpendicular to a least one location on the surface of interest of the object. 
     
     
         8 . The optical scanner as set forth in  claim 1  further comprising:
 a projection lens positioned to project the second light beam having the transmissive aperture pattern onto the mirror. 
 
     
     
         9 . The optical scanner as set forth in  claim 1 , wherein the housing has a width less than 25 mm. 
     
     
         10 . The optical scanner as set forth in  claim 1 , wherein the transmissive pattern is an ellipse, a line, or a cross-hair pattern. 
     
     
         11 . The optical scanner as set forth in  claim 1 , wherein the housing is sealed. 
     
     
         12 . The optical scanner as set forth in  claim 1 , wherein the light receiver comprises at least a lens and a photosensor. 
     
     
         13 . The optical scanner as set forth in  claim 12 , wherein the photosensor comprises at least one of a quadrant sensor, an image sensor, or a position sensing device. 
     
     
         14 . The optical scanner as set forth in  claim 1 , wherein the mirror is fixedly located within the housing. 
     
     
         15 . The optical scanner as set forth in  claim 14  further comprising a rotatable stage configured to support the housing and to be movable with respect to the object. 
     
     
         16 . The optical scanner as set forth in  claim 15 , wherein the rotatable stage is further configured to be translated along an axis. 
     
     
         17 . The optical scanner as set forth in  claim 16 , wherein the rotatable stage is configured to perform one or more rotations or translations to scan the second light beam over an entire surface area of the object to generate a three-dimensional image. 
     
     
         18 . The optical scanner as set forth in  claim 1 , wherein the mirror is a scanning mirror configured to rotate to scan the second light beam along at least one axis of the object. 
     
     
         19 . The optical scanner as set forth in  claim 18 , wherein the scanning mirror is a micro-electricalmechanical scanning mirror. 
     
     
         20 . The optical scanner as set forth in  claim 19 , wherein the micro-electromechanical scanning mirror is at least one of electrostatically or electromagnetically positioned within the housing. 
     
     
         21 . The optical scanner as set forth in  claim 19 , wherein the micro-electromechanical scanning mirror is configured to rotate to scan the second light beam along the at least one axis of the object at a rate of about 1000 scans/second. 
     
     
         22 . The optical scanner as set forth in  claim 19 , wherein the micro-electromechanical scanning mirror is configured to rotate to scan the second light beam along the at least one axis of the object at a rate of about 50 scans/second. 
     
     
         23 . The optical scanner as set forth in  claim 19 , wherein the micro-electromechanical scanning mirror is further configured to have a scan pattern which is a raster pattern. 
     
     
         24 . A method of making an optical scanner comprising:
 providing an opaque reticle with an aperture positioned to receive a first light beam emitted from a light source and transmit a second light beam that forms a transmissive pattern;   positioning a mirror to receive the second light beam and reflect the second light beam onto a surface of interest of an object; and   positioning a light receiver to receive a third light beam from the surface of interest of the object, wherein the light receiver is configured to obtain one or more light position values to determine a parameter of the surface of interest of the object.   
     
     
         25 . The method as set forth in  claim 24 , wherein the light source is a light emitting diode, a semiconductor laser, or a pulsed light source. 
     
     
         26 . The method as set forth in  claim 24 , wherein the light source has a wavelength of less than 500 nm. 
     
     
         27 . The method as set forth in  claim 24  further comprising:
 positioning an imaging lens to receive the third light beam from the surface of interest of the object and deliver the third light beam to the light receiver. 
 
     
     
         28 . The method as set forth in  claim 27 , wherein the imaging lens is telecentric in object space. 
     
     
         29 . The optical scanner as set forth in  claim 27  further comprising:
 positioning an optical filter configured to transmit substantially only light of a wavelength emitted by the light source between the imaging lens and the light receiver. 
 
     
     
         30 . The method as set forth in  claim 27 , wherein the imaging lens is positioned with an axis of the imaging lens substantially perpendicular to a least one location on the surface of interest of the object. 
     
     
         31 . The method as set forth in  claim 24  further comprising:
 positioning a projection lens to project the second light beam having the transmissive aperture pattern onto the mirror. 
 
     
     
         32 . The method as set forth in  claim 24 , wherein the housing has a width less than 25 mm. 
     
     
         33 . The method as set forth in  claim 24 , wherein the transmissive pattern is an ellipse, a line, or a cross-hair pattern. 
     
     
         34 . The method as set forth in  claim 24 , wherein the light receiver comprises at least a lens and a photosensor. 
     
     
         35 . The method as set forth in  claim 34 , wherein the photosensor comprises at least one of a quadrant sensor, an image sensor, or a position sensing device. 
     
     
         36 . The method as set forth in  claim 24 , wherein positioning the mirror comprises fixedly locating the mirror. 
     
     
         37 . The method as set forth in  claim 36  further comprising:
 providing a rotatable stage configured to support the optical scanner and to be movable with respect to the object; and 
 coupling the optical scanner to the rotatable stage. 
 
     
     
         38 . The method as set forth in  claim 37 , wherein the rotatable stage is further configured to be translated along an axis. 
     
     
         39 . The method as set forth in  claim 38 , wherein the rotatable stage is configured to perform one or more rotations or translations to scan the second light beam over an entire surface area of the object to generate a three-dimensional image. 
     
     
         40 . The method as set forth in  claim 24 , wherein the mirror is a scanning mirror configured to rotate to scan the second light beam along at least one axis of the object. 
     
     
         41 . The method as set forth in  claim 40 , wherein the scanning mirror is a micro-electricalmechanical scanning mirror. 
     
     
         42 . The method as set forth in  claim 41 , wherein the positioning the micro-electromechanical scanning mirror in the housing comprises at least one of electrostatically or electromagnetically positioning the electromechanical scanning mirror within the housing. 
     
     
         43 . The method as set forth in  claim 41 , wherein the micro-electromechanical scanning mirror is configured to rotate to scan the second light beam along the at least one axis of the object at a rate of about 1000 scans/second. 
     
     
         44 . The method as set forth in  claim 41 , wherein the micro-electromechanical scanning minor is configured to rotate to scan the second light beam along the at least one axis of the object at a rate of about 50 scans/second. 
     
     
         45 . The method as set forth in  claim 41 , wherein the micro-electromechanical scanning mirror is further configured to have a scan pattern which is a raster pattern. 
     
     
         46 . The method as set forth in  claim 24  further comprising:
 positioning a second reticle having a second aperture to receive a fourth light beam emitted from a second light source, the second reticle configured to transmit a fifth light beam through the second aperture; and 
 positioning a second mirror to receive the fifth light beam transmitted from the second reticle and reflect the fifth light beam onto the surface of interest of the object, wherein the light receiver is positioned to receive a sixth light beam from the surface of interest of the object and is configured to obtain one or more light position values to determine the parameter of the surface of interest of the object based on both the third light beam and the sixth light beam.