Sub-pixel grayscale three-dimensional printing

Abstract

Techniques and systems for sub-pixel grayscale three-dimensional (3D) printing are described. A technique includes mapping a 3D digital model onto a 3D grid of voxels associated with a 3D printer; assigning a first intensity level to first voxels that are fully contained within the model, the first intensity level being sufficient to cure photoactive resin during a curing time; determining, based on geometric information provided by the model, containment degrees for second voxels that are partially contained within the model; assigning second intensity levels to the second voxels based respectively on the containment degrees, the second intensity levels being greater than a third intensity level and lesser than the first intensity level; assigning the third intensity level to third voxels that are outside of the model; and generating one or more graphic files based on the first, second, third voxels, and respectively assigned intensity levels.

1 .- 28 . (canceled) 
     
     
         29 . A method for processing a three-dimensional (3D) object for printing by a 3D printer, comprising:
 (a) obtaining, by a computer processor, a digital model corresponding to at least a portion of said 3D object;   (b) generating, by said computer processor, a scaled digital model by scaling said digital model based on a plurality of scaling factors, wherein said plurality of scaling factors comprises a first scaling factor for a first axis and a second scaling factor for a second axis, wherein said first scaling factor and said second scaling factor are different; and   (c) generating, by said computer processor, a plurality of digital slices corresponding to said scaled digital model, wherein said plurality of digital slices are usable to produce a computer instruction for printing by said 3D printer.   
     
     
         30 . The method of  claim 29 , wherein said plurality of scaling factors comprises a third scaling factor for a third axis, wherein each of said plurality of scaling factors are different. 
     
     
         31 . The method of  claim 29 , wherein a digital slice of said plurality of digital slices corresponds to a grid of voxels. 
     
     
         32 . The method of  claim 31 , wherein a voxel of said grid of voxels is characterized by having a first size along said first axis and a second size along said second axis, wherein said first size and said second size are different. 
     
     
         33 . The method of  claim 32 , wherein a size of said voxel along a z-axis is different than that along a x-axis or a y-axis. 
     
     
         34 . The method of  claim 31 , further comprising assigning a light intensity level for a voxel of said gird of voxels based on a portion of said voxel that is contained within said scaled digital model. 
     
     
         35 . The method of  claim 29 , wherein a digital slice of said plurality of digital slices corresponds to a grid of pixels. 
     
     
         36 . The method of  claim 35 , further comprising assigning a light intensity level for a pixel of said gird of pixels based on a portion of said pixel that is contained within said scaled digital model. 
     
     
         37 . The method of  claim 29 , further comprising selectively modifying a sub-population of said plurality of digital slices. 
     
     
         38 . The method of  claim 29 , wherein said computer instruction is usable by said 3D printer to print at least a portion of said 3D object from a photoactive resin at sub-pixel precision. 
     
     
         39 . A system for processing a three-dimensional (3D) object for printing by a 3D printer, comprising:
 a computer processor in digital communication with a computer memory, wherein said computer processor is configured to:   (a) obtain a digital model corresponding to at least a portion of said 3D object;   (b) generate a scaled digital model by scaling said digital model based on a plurality of scaling factors, wherein said plurality of scaling factors comprises a first scaling factor for a first axis and a second scaling factor for a second axis, wherein said first scaling factor and said second scaling factor are different; and   (c) generate a plurality of digital slices corresponding to said scaled digital model, wherein said plurality of digital slices are usable to produce a computer instruction for printing by said 3D printer.   
     
     
         40 . The system of  claim 39 , wherein said plurality of scaling factors comprises a third scaling factor for a third axis, wherein each of said plurality of scaling factors are different. 
     
     
         41 . The system of  claim 39 , wherein a digital slice of said plurality of digital slices corresponds to a grid of voxels. 
     
     
         42 . The system of  claim 41 , wherein a voxel of said grid of voxels is characterized by having a first size along said first axis and a second size along said second axis, wherein said first size and said second size are different. 
     
     
         43 . The system of  claim 42 , wherein a size of said voxel along a z-axis is different than that along a x-axis or a y-axis. 
     
     
         44 . The system of  claim 41 , wherein said computer processor is configured to assign a light intensity level for a voxel of said gird of voxels based on a portion of said voxel that is contained within said scaled digital model. 
     
     
         45 . The system of  claim 39 , wherein a digital slice of said plurality of digital slices corresponds to a grid of pixels. 
     
     
         46 . The system of  claim 45 , wherein said computer processor is configured to assign a light intensity level for a pixel of said gird of pixels based on a portion of said pixel that is contained within said scaled digital model. 
     
     
         47 . The system of  claim 39 , wherein said computer processor is configured to selectively modify a sub-population of said plurality of digital slices. 
     
     
         48 . The system of  claim 39 , wherein said computer instruction is usable by said 3D printer to print at least a portion of said 3D object from a photoactive resin at sub-pixel precision.