Digital Light Processing Projector Research Articles

Cost-Effective Laboratory Matrix Projection Micro-Lithography System.

This paper presents a home-built projection lithographer designed to transfer the image from a DLP (digital light processing) projector MEMS matrix onto the microscope objective's field of view, where a photoresist-covered substrate is placed. The photoresist is exposed using blue light with a wavelength of 450 nm. To calibrate the device and adjust focal lengths, we utilize a red light that does not affect the photoresist. The substrate is located on a movable platform, allowing the exposure field to be shifted, enabling the exposure of designs with lateral sizes of 1 × 1 cm2 at a resolution of a few micrometers. Our setup showcases a 2 μm resolution for the single frame 200 × 100 μm2, and a 5 μm resolution for 1 × 1 cm2 with field stitching. The exposure speed, approximately 1 mm2/100 s, proves to be sufficient for a variety of laboratory prototyping needs. This system offers a significant advantage due to its utilization of easily accessible and budget-friendly components, thereby enhancing its accessibility for a broader user base. The exposure speed and resolution meet the requirements for laboratory prototyping in the fields of 2D materials, quantum optics, superconducting microelectronics, microfluidics, and biology.

A Polarized Structured Light Method for the 3D Measurement of High-Reflective Surfaces

The reflection phenomenon exhibited by highly reflective surfaces considerably affects the quality of captured images, thereby rendering the task of structured light (SL) 3D reconstruction. In this paper, a polarized SL method is proposed to address the reconstruction issues on high-reflectance surfaces. The SL system we build in this paper involves a four-channel polarizing camera and a digital light processing (DLP) projector equipped with a polarizer in the lens. The built system enables the simultaneous acquisition of four groups of fringe images, each with different brightness differences. Then, a binary time-multiplexing SL method is adopted to obtain four distinct point clouds. Additionally, a fusion algorithm is proposed to merge the four point clouds into a single, precise, and complete point cloud. Several experiments have been conducted to demonstrate that the proposed method is capable of achieving excellent reconstruction outcomes on highly reflective surfaces.

Preparation of large-size alumina ceramic parts by DLP 3D printing using high-solid-loading paste and optimizing the debinding process

Digital light processing (DLP) is a promising additive manufacturing method for creating complex structural alumina ceramic with high precision, high efficiency, and low cost. However, printing large-size parts with high feature resolution by DLP, obtaining high-performance pastes, and optimizing the debinding process are challenges that still need to be overcome. In this study, an advanced top-down Matrix-DLP technology that seamlessly connects two high-definition-resolution DLP projectors, with high resolution and a large projection area, was used to achieve fine-structured large-size alumina green bodies. The homogeneous and stable non-self-levelling alumina pastes suitable for the DLP technology were developed, with a high solid loading up to 55 vol%, viscosity of 35.0 Pa s at 30 s−1, and good rheological properties by innovatively using 2.5 wt% P5318 as surface modifiers of alumina powders and with only a 0.244% volume of bubble residue by using 0.5 wt% BYK-066N defoamer in combination with a vacuum planetary stirring defoaming process. The debinding processes were designed based on TG-DSC analysis and then optimized, and it was proved that the segmented-atmosphere debinding process was the best approach and can obtain defect- and carbon residue-free bodies with uniform grain distribution, and can also achieve non-destructive debinding for the thick-walled parts with thickness greater than 10 mm. The effects of the debinding residual carbon and the solid loading on the microstructure and properties after sintering were also investigated. Consequently, the high-precision large-size alumina ceramic with good interlayer bonding, dense microstructure, and high microhardness of 17.92 GPa was obtained.

Optical Engine Design for a Compact, High-Luminance DLP Projector Using Four-Channel LEDs and a Total Internal Reflection Prism

How to obtain higher brightness with a small volume projection engine for 4K resolution digital light processing (DLP) is of great significance. In this paper, we first use the fourth channel serving as a blue pump leading to a 52% gain of green brightness. Secondly, a new inline total internal reflection prism glued with a spherical mirror is constructed to notably reduce the length of the relay illumination system by more than 10 mm, resulting in a more compact optical engine with a volume of 210 × 140 × 36 mm3. Thirdly, a projection lens is optimized with a modulation transfer function higher than 0.6 at 93 lines for a distance of 2125 mm with distortion lower than 1%. As a result, the efficiencies of RGB lights are higher than 60%, and the luminance and uniformity on the screen reach 1412 lm and 94.5% measured by the prototype. Our proposed projection system is significantly helpful for designing a compact and high-luminance 4K DLP projection.

Quantum Dot Patterning and Encapsulation by Maskless Lithography for Display Technologies.

For their unique optical properties, quantum dots (QDs) have been extensively used as light emitters in a number of photonic and optoelectronic applications. They even met commercialization success through their implementation in high-end displays with unmatched brightness and color rendering. For such applications, however, QDs must be shielded from oxygen and water vapor, which are known to degrade their optical properties over time. Even with highly qualitative QDs, this can only be achieved through their encapsulation between barrier layers. With the emergence of mini- and microLED for higher contrast and miniaturized displays, new strategies must be found for the concomitant patterning and encapsulation of QDs, with sub-millimeter resolution. To this end, we developed a new approach for the direct patterning of QDs through maskless lithography. By combining QDs in photopolymerizable resins with digital light processing (DLP) projectors, we developed a versatile and massively parallel fabrication process for the additive manufacturing of functional structures that we refer to as QD pockets. These 3D heterostructures are designed to provide isotropic encapsulation of the QDs, and hence prevent edge ingress from the lateral sides of QD films, which remains a shortcoming of the current technologies.

A dual-projector three-dimensional measurement model for shading problem of micro-scale object complex surface

Considering the inherent defects of the traditional triangulation method, always a shadow area is produced in the image collected by the camera. In this work, based on the traditional monocular vision measurement system, an auxiliary light source was added to alleviate the shadow problem. Two symmetrical digital light processing (DLP) projectors were also employed to project the modulated monochrome red fringe patterns and the monochrome blue fringe patterns onto the object, whereas the distorted fringe patterns were captured by the colour camera. The image collected by the colour camera was separated, whereas the deformation fringe information of the measured object was obtained in the red channel and blue channel, respectively. Fusion of red and blue channels information to eliminate measurement shadows. From the experimental results, the root mean square error (RMSE) of the system was about 6µm, and this method can effectively solve the shadow problem in small object measurement.

Assessment of digital light processing (DLP) projector stimulators for visual electrophysiology

IntroductionVisual electrophysiology tests require the use of precise and calibrated visual display units (VDUs). Existing VDUs for presenting structured stimuli are now mostly obsolete, with modern solutions limited or unsuitable for clinical testing. Digital light processing (DLP) laser projectors have recently become commercially available and this study aimed to assess their suitability as VDUs for visual electrophysiology testing.MethodsThis study consisted of two sections. The first was a photometric study of two DLP laser projectors (Viewsonic LS831WU and HiSense 100L5FTUK) to assess luminance, contrast, spectral and temporal characteristics of the stimulus. The second was a physiological study comparing pattern electroretinograms (PERG) and visual evoked potentials (PVEPs) amplitudes and peak-times recorded using a DLP laser projector, photometrically and spatially matched to existing plasma VDUs at our institution (Pioneer Electronics Corporation, PDP422MXE).ResultsThe Viewsonic DLP laser projector was capable of high luminance levels (0–587.5 cd/m2) whilst maintaining contrast above 93%. The temporal properties showed fast rise and fall times of 0.5–1 ms and 0.5–1 ms, respectively, without any transient luminance change with reversals. The device required a warm-up time of at least 2 min until reaching near maximal luminance. The second (Hisense) device was observed to have a detrimental input lag jitter so was not used for any further analysis. PERGs and PVEPs showed high agreement and correlation (r = 0.766–0.905) between the Viewsonic DLP device and existing plasma VDUs. No significant differences were observed for P50 and P100 peak-time (p = > 0.05), however P50, N95 and P100 amplitudes were all significantly larger for the DLP device (p = < 0.05).DiscussionThe DLP laser projector tested in this study is a viable and practical replacement VDU for clinical electrophysiology tests of vision. The device is easily capable of meeting ISCEV standards, and showed PERG and PVEP amplitudes larger than existing systems despite photometric and spatial matching. The DLP laser projectors are capable of very large field sizes so are beneficial for paediatric testing or those wishing to examine large field responses. Importantly, it was observed that some devices may suffer input lag jitter, therefore, individual calibration and assessment of DLP projection systems is an important consideration before clinical implementation.

Highlights from the Detroit SID Vehicle Display Symposium and Exposition

Highlights from the Detroit SID Vehicle Display Symposium and Exposition

Spatial frequency domain Mueller matrix imaging.

Mueller matrix polarimetry (MMP) and spatial frequency domain imaging (SFDI) are wide-field optical imaging modalities that differentiate tissue primarily by structure alignment and photon transport coefficient, respectively. Because these effects can be related, combining MMP and SFDI may enhance tissue differentiation beyond the capability of each modality alone. An instrument was developed to combine MMP and SFDI with the goal of testing whether it enhances contrast of features in reflection mode. The instrument was constructed using liquid crystal elements for polarization control, a digital light processing projector for generating sinusoidal illumination patterns, and a digital camera for imaging. A theoretical analysis shows that the SFD Mueller matrix is complex-valued and does not follow the same behavior as a regular Mueller matrix. Images were acquired from an anisotropic tissue phantom, an optical fiber bundle, and cerebellum, thalamus, and cerebrum tissues. The measurement results suggest that singly scattered, few scattered, and diffusely scattered photon paths can be distinguished in some of the samples investigated. The combined imaging modality yields additional spatial frequency phase information, which highlights paths having only a few scattering events. The combination of MMP and SFDI offers contrast mechanisms inaccessible by each modality used alone.

A five-primary Maxwellian-view display for independent control of melanopsin, rhodopsin, and three-cone opsins on a fine spatial scale.

Independent spatiotemporal control of the stimulation of the five photoreceptor classes requires a display with as many primary lights to probe their isolated spatial and temporal responses. No such system exists with suitable performance properties. We present a system to construct a five-primary display from commercially available three-primary digital light processing projectors. It optimizes the set of five primary lights required to maximize the achievable contrast of a single photoreceptor class in a silent substitution protocol, including where the background chromaticity is first specified. From these chosen five primaries, we describe a method to convert complex three-primary (RGB) images to five-primary representations with complete specification of the photoreceptor excitations at each pixel. Key to enabling this multiple display system with a single HDMI connection is a novel control protocol implemented in a deterministic field-programmable gate array controller that splits the data into five video streams to allow nearly synchronous presentation of primary image data through multiple displays. Each pixel is controlled over 9.5 bits for each primary over a single frame for measurement of threshold-level vision. In addition to a large contrast gamut, the Maxwellian view offers high retinal illumination to support the investigation of five opsin-based responses to complex spatiotemporal images with a truly silent substitution protocol, while avoiding the confounding effects of uncontrolled photoreceptor excitations as occurs in four-primary systems. The customizable primaries facilitate this display translation to species with different photoreceptor spectral responses, and the optics are designed for integration into microscopes for use as a stimulus generator in physiological experiments.

Spectroscopic imaging ellipsometry for two-dimensional thin film thickness measurement using a digital light processing projector

An improved version of spectroscopic imaging ellipsometry is described for accurate reconstruction of two-dimensional thin film thickness. A digital light processing projector enables a selected area of the back focal plane of the objective lens to be illuminated so that the angle of incidence and the polarization state of the light source vary depending on the area of the back focal plane being illuminated. By combining multiple images of the object plane obtained at different polarization states, every pixel in the field of view has its own ellipsometric parameters; therefore a reconstruction of two-dimensional thin film thickness is possible. Because the proposed ellipsometry system has a co-axial optical structure in which the objective lens is arranged in the normal direction to the measurement target, the spatial resolution is improved due to the application of a high-magnitude objective lens. In addition, spectroscopic analysis can be conducted using a number of band-pass filters which each have a central wavelength. The effect of the proposed method on thin film thickness measurement was evaluated by comparing the experimental results with a topographic profile obtained using a commercial atomic force microscope.

Multidimensional surface patterning based on wavelength-controlled disulfide-diselenide dynamic photochemistry

Controlling surface properties in a spatiotemporal and reversible manner is highly attractive for novel functional surfaces, as it allows them to act in a much smarter way. Surface modification strategies based on photochemical metathesis reactions are seemed as promising solutions for such demands, due to their high spatiotemporal controllability and the perfect reversibility. In this paper, we demonstrate a powerful strategy to precisely manipulate the surface functions by the combination of wavelength-controlled disulfide-diselenide dynamic photochemistry and a 405 nm digital light processing (DLP) projector. We show that, by this method, the arrangement of chemical moieties on a disulfide surface can be exactly controlled, leading to complex patterned surfaces with multinary and grayscale molecular distributions. Moreover, owing to the wavelength-dependent reactivity of the -S-S- and -S-Se- groups, the surface functions can be selectively and dynamically adjusted by light with different colors (wavelength). Based on these unique features, the chemical moieties on every point of the surface can be exactly controlled and dynamically manipulated by our strategy, making the generated surfaces quite versatile and smart. We demonstrate the successful application of this method in high-level information encryption and transformation.

Technological Proficiency Level of English Faculty Members of a Philippine State University: Application of Cognition Learning Approaches

In today’s digital society, the role of teachers in the classroom has technologically challenged them over the past so many years. New technological tools including interactive videos, digital light processing projectors, and other significant appurtenances of digital learning have become more prevalent amidst its essential impulse to the millennial learners. In conjunction with this, teachers must delve into innovative teaching strategies and how to effectively integrate them into the classroom and adapt these methods with the new digital learning devices. The study notes that teacher technological performance can affect the meaningful change in the pedagogical setup and that learning with the aid of technology is a more interactive and effective process of learning acquisition. The effective use of modern equipment in teaching relies mainly on the exposure of a certain teacher in seminars, training, and other related professional skills of advanced technologies. Under this circumstance, many teachers are still using the conventional way of teaching and perhaps some of them will never intend to use technology as a supplement or rather as a core component of instruction. This study provided a modest understanding of the technological proficiency of the target respondents and the opportunity to know their proficiency level in the utilization of advanced technologies. Henceforth, the study revealed the technological proficiency level of the respondents through the use of digital devices and the integration of these available instructional tools in their classes.&#x0D; Keywords: Technological Proficiency, Situated Cognition, Distributed Cognition, Socially Shared Cognition, Cognition Learning Theory

Vision vibration measurement based on coded illumination in a single frame

A vision-based mechanical vibration measurement method is presented and verified by experiments in this paper. The coded illumination is projected on the objects by a digital light processing projector with a digital micromirror device in it. The projection patterns are designed to be concentric. In one integration time of the camera, the projector is exposed several times, which embeds temporal information in the images. A single frame can be divided into subframes by separating the coded concentric patterns. The centroids of the coded concentric patterns are fitted, and the centroids are treated as virtual feature points with vibration information. The acquisition devices are common low-speed cameras, and they record the vibration whose frequency exceeds the camera frame rate. The temporal resolution is increased by 10 times, corresponding to the 400 Hz sampling frequency in the experiment. We can measure the vibration of multiple points with different sampling frequencies. The frequency measurement accuracy is in the subhertz level in low-frequency measurement, relative error is always slightly greater than 0.01 in high-frequency measurement, and the amplitude resolution is 130 µm.

Projection optical engine design based on tri-color LEDs and digital light processing technology.

Digital light processing (DLP) is currently a cutting-edge technology for desktop projection optical engines. Due to the passive luminescence characteristics, the DLP projection engine needs a few specific illumination optical components for light collimation, homogenization, and color combination, together with a projection lens matching the DLP chip and magnifying the image. In this paper, we propose a design approach that first splits the DLP projection optical engine into individual components for separate design, and then integrates them into a whole system for further verification. For the first step, the collimating lens group is designed for light collection, and the dichroic mirrors are used to fold the light path based on tri-color LED light sources. For the second step, a fly-eye lens and the corresponding relay lens group are designed to achieve uniform illumination on the DMD chip. The third step is to optimize the projection lens group for high-resolution projection display. Based on the design and simulation, the optical efficiency is 63.4% and the uniformity reaches 94.9% on the projection screen. The modulation transfer function (MTF) of the projection lens is higher than 0.4 at 66 lines for the distance of 500∼1500mm, and the distortion is lower than 1%. Simulation results show that the total luminous flux is estimated to reach 224.15 lm when the powers of tri-color LEDs are 21 W, 15.5 W, and 25 W, respectively. A projector prototype is built and tested for further verification, which provides a luminous flux of 220.43 lm and uniformity of 90.22%, respectively. The proposed design, demonstrated by both simulation and experiment, exhibits high feasibility and application potential in state-of-the-art commercial projector design.

Biofabrication of Cell-Laden Gelatin Methacryloyl Hydrogels with Incorporation of Silanized Hydroxyapatite by Visible Light Projection.

Gelatin methacryloyl (GelMA) hydrogel is a photopolymerizable biomaterial widely used for three-dimensional (3D) cell culture due to its high biocompatibility. However, the drawback of GelMA hydrogel is its poor mechanical properties, which may compromise the feasibility of biofabrication techniques. In this study, a cell-laden GelMA composite hydrogel with a combination incorporating silanized hydroxyapatite (Si-HAp) and a simple and harmless visible light crosslinking system for this hydrogel were developed. The incorporation of Si-HAp into the GelMA hydrogel enhanced the mechanical properties of the composite hydrogel. Moreover, the composite hydrogel exhibited low cytotoxicity and promoted the osteogenic gene expression of embedded MG63 cells and Human bone marrow mesenchymal stem cells (hBMSCs). We also established a maskless lithographic method to fabricate a defined 3D structure under visible light by using a digital light processing projector, and the incorporation of Si-HAp increased the resolution of photolithographic hydrogels. The GelMA-Si-HAp composite hydrogel system can serve as an effective biomaterial in bone regeneration.

Multi-material stereolithography using curing-on-demand printheads

Purpose This paper aims to present a multi-material additive manufacturing (AM) process with a newly developed curing-on-demand method to fabricate a three-dimensional (3D) object with multiple material compositions. Design/methodology/approach Unlike the deposition-on-demand printing method, the proposed curing-on-demand printheads use a digital light processing (DLP) projector to selectively cure a thin layer of liquid photocurable resin and then clean the residual uncured material effectively using a vacuuming and post-curing device. Each printhead can individually fabricate one type of material using digitally controlled mask image patterns. The proposed AM process can accurately deposit multiple materials in each layer by combining multiple curing-on-demand printheads together. Consequently, a three-dimensional object can be fabricated layer-by-layer using the developed curing-on-demand printing method. Findings Effective cleaning of uncured resin is realized with reduced coated resin whose height is in the sub-millimeter level and improved vacuum cleaning performance with the uncleaned resin less than 10 µm thick. Also, fast material swapping is achieved using the compact design of multiple printheads. Originality/value The proposed multi-material stereolithography (SL) process enables 3D printing components using more viscous materials and can achieve desired manufacturing characteristics, including high feature resolution, fast fabrication speed and low machine cost.

High-accuracy projector calibration method for fringe projection profilometry considering perspective transformation.

Camera and projector are the key components of structured light three-dimensional (3-D) measurements, and Digital Light Processing (DLP) projector has been widely used for projecting digital structured light patterns for the measurement. The light projecting of projectors can be modeled as the inverse procedures of camera imaging, and its high-accuracy calibration is still a remaining challenge. Therefore, this paper proposes a novel projector calibration method to improve the calibration accuracy of DLP projector. By fixing the position of the camera and calibration board, this method essentially eliminates the perspective transformation error and effectively avoids the distortion of the extracted marker points. The proposed projector calibration procedures are given as follows: Firstly, the optical axis of the camera is adjusted parallel to the normal of the hollow ring calibration board, and a texture image is captured by the camera; Secondly, the horizontal and vertical fringe patterns with nine different positions and directions are projected onto the calibration board, and nine sets of projected images are taken; Finally, a one-to-one correspondence between the camera and the projector is established, and the projector is accurately calibrated using the phase equivalence. The experimental results show that the proposed projector calibration method is feasible and easy to operate, which can essentially eliminate the perspective transformation error and ensure the competitive accuracy.

High-resolution linearity measurements of photovoltaic devices using digital light processing projection

Although photovoltaic (PV) devices are rated at standard testing conditions (STCs), these STCs are rarely met, either outdoors, or when PV devices are used for indoor applications. Thus, it is beneficial to fully characterise the linearity of PV devices with respect to irradiance. Moreover, high accuracy linearity measurements are essential for reference cells (RCs), as they ensure the precision of the measured irradiance. This work presents a new technique for linearity measurements of PV devices based on digital light processing (DLP). The proposed system uses a digital micromirror device coupled with projection optics and a high-power LED array. By creating a series of patterns projected on the device under test with a specific number of bright and dark pixels, linearity measurements can be implemented through a spatial dithering process. Since the dithering process is mechanical, it is expected that any spectral variability effects for the different dithering levels or electrical non-linearities of the light source are avoided. The developed system can provide thousands of measurement points on the linearity curve of a device in seconds, which is impossible with any other currently established methods. Measurements of RCs with known linearity curves are acquired and are validated by conventional methods. Results demonstrate that the DLP method provides equal measurement accuracy compared to conventional systems, but at significantly higher resolution (points on the linearity curve) and order of magnitude higher measurement speed.

Fabrication and Compressive Behavior of a Micro-Lattice Composite by High Resolution DLP Stereolithography.

Lattice structures are superior to stochastic foams in mechanical properties and are finding increasing applications. Their properties can be tailored in a wide range through adjusting the design and dimensions of the unit cell, changing the constituent materials as well as forming into hierarchical structures. In order to achieve more levels of hierarchy, the dimensions of the fundamental lattice have to be small enough. Although lattice size of several microns can be fabricated using the two-photon polymerization technique, sophisticated and costly equipment is required. To balance cost and performance, a low-cost high resolution micro-stereolithographic system has been developed in this work based on a commercial digital light processing (DLP) projector. Unit cell lengths as small as 100 μm have been successfully fabricated. Decreasing the unit cell size from 150 to 100 μm increased the compressive stiffness by 26%. Different pretreatments to facilitate the electroless plating of nickel on the lattice structure have been attempted. A pretreatment of dip coating in a graphene suspension is the most successful and increased the strength and stiffness by 5.3 and 3.6 times, respectively. Even a very light and incomplete nickel plating in the interior has increase the structural stiffness and strength by more than twofold.