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Synopsis

Patent US 9,076,570 B2 describes an apparatus and method for dynamic calibration of an optical scanner for non-planar surfaces. This invention addresses a significant limitation in optical scanning technology by enabling precise, real-time calibration of a scanner to accurately capture the geometry and surface characteristics of objects with complex, non-flat shapes. This is a crucial advancement for applications requiring high-fidelity digital representations of physical objects.

A key novel aspect of this invention is its dynamic calibration capability. Unlike conventional scanners that are typically calibrated for planar surfaces or require laborious, static recalibration for curved objects, this system integrates a real-time feedback mechanism. The patent details a method where the scanner can continuously adjust its parameters (e.g., focus, illumination, sensor alignment) based on the varying distance and orientation to a non-planar surface as it is being scanned. This is achieved by incorporating sensors that measure the scanner's position and orientation relative to the object, and a control system that uses this information to dynamically optimize the scanning parameters. The result is significantly improved accuracy and efficiency when digitizing three-dimensional objects with complex geometries, eliminating artifacts or distortions common in conventional methods.

The commercial potential for this dynamic optical scanner calibration system is substantial across diverse industries requiring precise 3D data capture:

• Reverse Engineering and Product Design: Manufacturers can rapidly and accurately digitize physical prototypes, existing parts, or even competitor products with complex curvatures. This speeds up design cycles, facilitates modifications, and enables rapid prototyping with high precision.

• Quality Control and Inspection: In industries such as automotive, aerospace, and medical device manufacturing, stringent quality control is essential. This system can perform highly accurate 3D inspection of parts with intricate geometries, detecting deviations from design specifications and ensuring product integrity, thereby reducing defects and rework.

• Cultural Heritage Preservation and Archiving: Museums and archives can create highly detailed 3D digital replicas of artifacts, sculptures, and historical objects, including those with delicate or irregular surfaces. This aids in preservation, research, virtual exhibitions, and public access without physical handling.

• Medical and Dental Applications: The technology can be used for precise 3D scanning of body parts for custom prosthetics, orthotics, or surgical planning. In dentistry, it can accurately capture dental impressions for custom aligners, crowns, and bridges, improving fit and patient comfort.

• Virtual Reality (VR) and Augmented Reality (AR) Content Creation: For creating realistic digital assets for VR/AR environments, gaming, or film production, the ability to rapidly scan real-world objects with high fidelity is invaluable. This system streamlines the creation of detailed 3D models with accurate textures.

• Forensics and Accident Reconstruction: In forensic analysis or accident investigations, precise 3D scans of crime scenes or damaged vehicles can provide critical data for analysis and reconstruction, offering a more accurate and comprehensive record.

This invention offers a sophisticated and adaptable solution for optical scanning of non-planar surfaces, overcoming traditional limitations to deliver unprecedented accuracy and efficiency in 3D data acquisition. It provides a foundation for numerous applications requiring high-fidelity digital representations of complex physical objects.