Methods of automatic geometric calibration using laser scanning reflectometry

1. A method of using a solid-imaging system to form a three-dimensional object using a scanning light beam, comprising:

a) operably disposing a calibration plate in the system where the object is formed, the calibration plate having a plurality of fiducial marks formed on a first surface comprising a light-absorbing material, wherein the fiducial marks are configured to scatter the actinic light;

b) scanning the light beam over the fiducial marks and detecting scattered light therefrom so as to measure corresponding center positions of the scanned fiducial marks; and

c) forming the object by directing the light beam based on the measured center positions.

2. The method of claim 1 , further comprising, prior to scanning the light beam over the fiducial marks, performing an initial light beam scan over first and second orthogonal rows of fiducial marks and detecting scattered light therefrom so as to establish a first coordinate system.

3. The method of claim 2 , further comprising, prior to forming the object, interpolating the measured center positions and the angular positions of the mirrors to establish a calibrated relationship between mirror angular positions and (x,y) positions where the object is formed, and then using the calibrated relationship to form the object.

4. The method of claim 2 , wherein the light beam is a laser beam having an adjustable spot size.

5. The method of claim 4 , further comprising:

adjusting the laser beam spot size so that it is has a larger width during the initial light beam scan than during the scanning of the light beam over the fiducial marks to measure corresponding center positions of the scanned fiducial marks.

6. The method of claim 1 , further comprising:

raster scanning one of the fiducial marks to establish a scanning contrast level.

7. The method of claim 1 , further comprising, prior to operably disposing a calibration plate in the system, forming the calibration plate using a photo-anodization process.

8. The method of claim 1 , wherein measuring of the corresponding center positions of the scanned fiducial marks includes applying at least one of a first parabolic approximation and a centroid approximation to the detected scattered light from the scanned fiducial marks.

9. A method of calibrating a solid-imaging system that forms a three-dimensional object and that has a mirror-based optical system having mirrors with adjustable angular positions for steering a light beam having an actinic wavelength and that has an elevator system that movably supports a build platform having a corresponding build plane, the method comprising:

(a) operably disposing a calibration plate onto the build platform, the calibration plate having a plurality of fiducial marks formed on a first surface comprising a light-absorbing material, wherein the fiducial marks are configured to scatter the actinic light;

(b) performing a first light beam scan over first and second orthogonal rows of fiducial marks and detecting scattered light therefrom so as to establish a first coordinate system;

(c) using the first coordinate system, performing a second light beam scan over at least a portion of the array of fiducial marks and detecting scattered light therefrom so as to measure corresponding center positions of the scanned fiducial marks; and

(d) interpolating the measured center positions and the angular positions of the mirrors to establish a calibrated relationship between mirror angular positions and (x,y) build plane positions.

10. The method of claim 9 , further comprising:

(e) using the interpolated relationship between the measured center positions and the angular positions of the mirrors and (x,y) positions at the build plane to steer the laser beam when forming the object.

11. The method of claim 9 , wherein the measured fiducial mark center positions are determined by raster scanning the fiducial marks in orthogonal directions.

12. The method of claim 9 , wherein measuring corresponding center positions of the scanned fiducial marks includes applying at least one of a first parabolic approximation and a centroid approximation to the detected scattered light from the scanned fiducial marks.

13. The method of claim 9 , wherein establishing the first coordinate system includes measuring values for at least one of rotation, scale and offset.

14. The method of claim 9 , further including prior to forming the object:

removing the calibration plate;

arranging a light-sensitive material on the build platform;

steering the laser beam using the interpolated relationship between the measured center positions and the angular positions of the mirrors and (x,y) positions at the build plane; and

measuring the pattern formed in the light-sensitive material to assess the quality of the calibration.

15. The method of claim 14 , wherein the light-sensitive material comprises MYLAR.

16. The method of claim 9 , wherein establishing the first coordinate system includes: calculating theoretical center positions of the scanned fiducial marks of the first light beam scan; and

calculating the theoretical centers of fiducial marks not scanned in the first light beam scan using interpolation.

17. The method of claim 9 , including forming the fiducial marks as either round dots, square dots, or hexagonal dots, wherein the dots have a diameter of about 0.030 inch with a center-to-center spacing of about 0.25 inch.

18. The method of claim 9 , wherein the light beam has an associated spot size, and wherein second light beam scan is performed with a spot size smaller than that used for the first light beam scan.

19. The method of claim 9 , further including:

rotating the calibration plate and repeating the first light beam scan over first and second orthogonal rows of fiducial marks and detecting scattered light therefrom so as to establish a third coordinate system; and

comparing the first and third coordinate systems and determining if there are differences therebetween that are indicative of one or more calibration plate errors.

20. The method of claim 9 , further including prior to performing the first laser beam scan:

raster scanning one of the fiducial marks to establish a scanning contrast level.