Fringe projection with a sinusoidal phase grating

Fringe projector with submillimeter fringe spacing at a meter-scale field of view

State-of-the-art fringe projection systems generate fringe patterns using digital light projectors (DLP). The axial uncertainty is limited by the smallest fringe period and is directly related to the pixel count. This results in limited accuracy of current DLP systems that affect applications such as in situ measurements for laser powder bed fusion systems, where a submillimeter fringe period is needed for field-of views larger than 500m m×500m m. This work presents a scalable fringe projection technique that enables the generation of stable fringe patterns over a large field of view spanning several meters while maintaining submillimeter fringe periods. This system uses geometric phase gratings to enable variable fringe spacing and fringe orientation capabilities. The system shears a coherent beam in the Fourier plane using a pair of geometric polarization gratings. The separation between the gratings directly affects the fringe spacing, and the orientation of the gratings affects the fringe orientation. The depth of focus is only limited by the coherence of the light source, enabling high fringe periods even on tilted planes. The system is designed with a single path configuration, making the system more robust to environmental noise. With a rotating linear polarizer, we demonstrate that phase-shifting methods could be employed to acquire phase information about the object. This paper employs a single-shot Fourier transform phase estimation technique to process the intensity maps acquired using projected fringe patterns. Further, we demonstrate the capabilities of the system to produce submillimeter fringe spacing and the ability to project fringes on larger scales for measurements.

Indoor and Outdoor Surface Measurement of 3D Objects under Different Background Illuminations and Wind Conditions Using Laser-Beam-Based Sinusoidal Fringe Projections

In this study, both theoretical analysis and experimental validation are carried out for 3D surface measurement under different indoor/outdoor environmental conditions via combining the projected laser-beam-based sinusoidal optical signal, the optical filtering technique, and the single-shot approach based on Fourier transform profilometry. The designed optical signal generator used in this work is capable of ensuring that the projected fringe pattern is monochromatic, higher-contrast, time-invariant, and truly sinusoidal. The proposed and developed optical setup of 3D surface measurement is portable and is used for in-situ experiments of 3D surface measurements that have been carried out under different sunlight illuminations. The experimental results indicate that accurate reconstructions of measured objects with even or varying surface reflectivity can be obtained under windy conditions and strong environmental illuminations such as the background illuminance of 5600–35,000 Lux. The generated fringe-pattern signal is not sensitive to vibrations from environmental influences including the effects of the wind, which has overcome the outdoor-measurement restrictions of the traditional interferometric system and the profilometry approaches based on phase-shifting methods.

Three-dimensional displacement in multi-colored objects

Three-dimensional displacement in multi-colored objects is measured by combining fringe projection (FP) and digital image correlation (DIC). Simultaneity of measurements through both techniques is warranted by encoding their signals on the RGB channels of color images. By separating the illuminating sources for each technique and by using ultraviolet light for DIC, contrast and amplitude of the registered signals are enhanced, enabling displacement measurement of multi-colored objects in dynamic events. The objects may even present a relatively large dynamic range of intensity levels. Proper selection of the light sources is supported by spectral analyses of the components of the system and by evaluation of the contrast of the registered images. Experimental results reveal that displacement measurements with relatively high accuracy can be obtained.

Relaxation of the Talbot condition in generalized grating imaging

We can form a grating image with two gratings having different pitches with an extended light source. It is called generalized grating imaging or the Talbot-Lau effect. When we want to obtain high contrast image with pure absorption gratings or pure phase gratings, the separation between the two gratings is restricted. This corresponds to the Talbot condition. In this paper, we propose to use a combination of absorption grating and phase grating to relax the separation restriction. The theory of generalized grating imaging is applied to the system with this kind of grating. Simulations are performed for calculating contrast variation and show that the proposed system practically relaxes the Talbot condition. An experiment verifies the result of the simulation.

Fringe projection profilometry based on a novel phase shift method

Fringe projection profilometry is generally used to measure the 3D shape of an object. In oblique-angle projection, the grating fringe cycle is broadened on the reference surface. A well-fitted, convenient, and quick cycle correction method is proposed in this study. Based on the proposed method, an accurate four-step phase shift method is developed. Comparative experiments show that the fringe projection profilometry based on the novel phase shift method can eliminate cycle error and significantly improve measurement accuracy. The relative error of the measurement is less than 1.5%. This method can be widely employed for measuring large objects.

Application of generalized grating imaging to pattern projection in three-dimensional profilometry

The theory of generalized grating imaging for a one-dimensional grating is applied to a pattern projection system in pattern projection profilometry. Contrast of the projected grating image is calculated under various conditions. The results help to determine the conditions suitable for obtaining high contrast grating images in a large space. Although the gratings required for the profilometry are hexagonal, the theory for two-dimensional gratings is prohibitively complex. Therefore, the projection system was designed using the one-dimensional theory. The projection system using two-dimensional hexagonal gratings was constructed and experiments were done with it. The result agrees approximately with the theoretical calculations for one-dimensional gratings. This suggests that the one-dimensional theory may be used for estimating the approximated behavior for hexagonal gratings for use in pattern projection profilometry. Some discussions are given for the application of the projection system for profiling the mannequin or human body.