3D-surface thermoform mapping (fabrication).
The present disclosure includes a method for modifying an input image to map to a three dimensional shape prior to forming the three dimensional shape. The method includes receiving by a processor at least two pre-forming images of a locally unique non-repeating pattern printed on an input material. The at least two pre-forming images are captured prior to the input material being formed into the three dimensional shape. The method further includes receiving by the processor at least two post-forming images of the pattern printed on the input material, wherein the post-forming images are captured after the input material has been formed into the three dimensional shape and analyzing by the processor the at least pre-forming images and the at least two post-forming images to determine a translation table.
FIELD(1) The present disclosure relates generally to vacuum-formed or thermoformed three-dimensional surfaces created from a thermoforming material with a two-dimensional printed image. More specifically, embodiments relate to systems and methods for producing accurate texture mapping or texture coordinates of the three-dimensional surfaces.BACKGROUND(2) Thermoforming is a manufacturing process where a plastic sheet is heated to an elevated temperature and is formed to a specific shape defined by a mold, and then is generally trimmed to create a product. The plastic sheet is heated to a high-enough temperature such that the sheet can be stretched into or onto a mold and then cooled to form a shaped product.(3) In some applications, an image, such as a two-dimensional (2D) printed image, is printed on a thermoforming material, such as a plastic sheet, which may then be thermoformed or vacuum-formed to produce a three-dimensional (3D) surface. The 2D image may be printed on the thermoforming material, such as the plastic sheet, by using vacuum formable inks. However, during the thermoforming process the 2D printed image may be distorted depending upon the complexity of the 3D shape (e.g., the geometry or surface curvature). Common methods for creating 3D surfaces using thermoforming processes or vacuum forming process may require a trial and error process to make adjustments to the 2D image to account for changes during the 3D forming process.(4) Various engineering software pr
1. A method for modifying an input image to map to a three dimensional shape prior to forming the three dimensional shape comprising: receiving by a processor data corresponding to a locally unique non-repeating pattern printed on an input material, wherein the data represents the pattern on the input material prior to the input material being formed into the three dimensional shape; receiving by the processor at least two post-forming images of the pattern printed on the input material, wherein the post-forming images are captured after the input material has been formed into the three dimensional shape, such that each pixel of the pattern is positioned at a three dimensional location; analyzing by the processor the locally unique pattern data and the at least two post-forming images to determine a translation table, wherein the translation table directly maps the three dimensional location of each pixel in the pattern on the three dimensional shape to a two dimensional location of each pixel in the pattern as printed on the input material; reconstructing by the processor a three dimensional shape with color from a two-dimensional print using the translation table; and forming by the processor a modified two dimensional print from the reconstructed three dimensional shape.
8. A method for modifying a two-dimensional (2D) texture for a vacuum-formed three dimensional surface (3D) comprising: receiving by a processor an image of a mapping pattern printed on an input material from at least two positions, the mapping pattern comprising a locally unique non-repeating pattern; receiving by the processor a 2D image of a 3D surface of the input material from the at least two positions, wherein the 3D surface is created by deforming the input material; determining by the processor a coordinate look-up table of the 3D surface corresponding to each pixel in the digital image of the mapping pattern from each of the at least two fixed positions, wherein the coordinate look-up table directly maps a 2D location of each pixel of the mapping pattern to a 3D location for each pixel of the mapping pattern; reconstructing by the processor a 3D shape with color from a 2D print from a 2D texture coordinate look-up table; and forming by the processor a modified 2D print from the reconstructed 3D shape.
16. A system for modifying an input image to print on a material before the material is formed to a three-dimensional shape comprising: a light source configured to light a surface of the material; one or more cameras configured to capture an image of a locally unique, non-repeating pattern printed on the material from at least two positions relative to the material; a computer in communication with the camera comprising a processor configured to perform the following operations: determining a 2D texture coordinate look-up table of a vacuum-formed 3D surface based, at least in part, on distortions in the locally unique, non-repeating pattern, wherein the 2D texture coordinate look-up table directly translates a 2D location of a select pixel in the pattern to a 3D location of the selected pixel on the 3D surface; and a printer in communication with the computer, wherein the printer prints a distorted 2D texture on a thermoforming material based on the 2D texture coordinate look-up table.
20. A method for producing a 3D surface with a distorted 2D texture, the method comprising: generating a modified 2D texture from an un-deformed 2D input texture according to a 2D texture coordinate look-up table for a vacuum formed 3D surface, wherein the 2D texture coordinate look-up table is formed by analyzing images of a locally unique non-repeating pattern printed on a sample thermoforming material and translates a pixel location for pixels in the pattern between a 2D location on the un-deformed 2D input texture to a 3D location on the formed 3D surface; printing the distorted 2D texture on a thermoforming material; and vacuum forming the thermoforming material into the 3D surface with a desired texture.
25. A method for producing a deformed two-dimensional (2D) texture for a vacuum-formed three dimensional surface (3D), the method comprising: capturing a digital image of a mapping pattern from at least two fixed positions, wherein the mapping pattern is printed on a planar input material, the mapping pattern comprising a locally unique non-repeating pattern; capturing a 2D image of a 3D surface from the at least two fixed positions, wherein the 3D surface is formed from the input material printed with the mapping pattern; generating a coordinate look-up table of the 3D surface corresponding to each pixel in the digital image of the mapping pattern from each of the at least two fixed positions, wherein the coordinate look-up table translates a 2D location of the pixels in the mapping pattern to a 3D location of the pixels on the 3D surface; reconstructing a 3D shape with color from a 2D print at coordinates provided by a 2D texture coordinate look-up table forming a modified 2D print from the reconstructed 3D shape.