High-accuracy 3D scanning
using Texas Instruments
DLP technology forstructured light®

Gina ParkDLP® Products Industrial Manager

Michael WangDLP Pico™ Products Marketing

Carey Ritchey
DLP Products Industrial Business Development Manager
Texas Instruments

Introduction
Three-dimensional (3D) scanning is a powerful tool that acquires volumetric data
leveraged for various metrology, inspection, detection and 3D imaging equipment.
Designers frequently opt for structured light systems based on TI DLP® technology
when they need very fast, high-accuracy scans with millimeter to micron resolution.
The emergence of 3D scanningsystems
Simple two-dimensional (2D) inspection systems
have been around for many years and generally
employ the technique of lighting an object, taking
a picture and comparing that image to a known“golden” 2D reference. 3D scanning adds the ability
to incorporate volumetric information. Introducing
z-dimension data enables measurements of volume,Figure 2. Optical 3D scanning with structured lightflatness or roughness. The ability to measurethese additional geometries—not captured by 2D

surface and combines the positional data fromsystems —is critical in industries such as printed

each point to create a 3D surface model (Figure 1).

circuit board (PCB), solder paste and machined part

Optical methods such as structured light (Figure 2)

inspection. It is also used for medical, dental andlater emerged for 3D scanning. Structured light ishearing aid manufacturing.

the process of projecting a series of patterns onto

Coordinate measurement machines (CMMs) werean object and capturing the pattern distortion with

one of the first industrial solutions to gather 3Da camera or sensor. A triangulation algorithm theninformation. A probe physically touches an object’s

calculates the data and outputs a 3D point cloud,which becomes the data for various calculations
in measurement, inspection, detection, modelingor machine vision systems. Optical 3D scanning is
popular because it does not touch the object being
measured and can be acquired very quickly, or evenin real time.

DLP technology enables fast, smart
light pattern generation
For optical 3D scanning equipment, DLP
technology is often used in systems as a source
for structured light. A DLP chip is an array of highlyreflective aluminum micromirrors known as a digital
micromirror device (DMD). When combining aFigure 1. Example of a coordinate measurement machine probe

High accuracy 3D scanning using 		
Texas Instruments DLP® technology for structured light2

September 2018

DMD with an illumination source and optics, thisMedicalsophisticated micro-electricalmechanical system

There has been explosive growth using 3D scanning(MEMS) can power various projection and spatial

technologies in the medical industry. Intra-oral

light modulation systems.

scanners (IOS), for example capture direct optical

Designers frequently select DLP technology for

impressions in dentistry (Figure 4). Micron-level 3D

structured light applications as the DMD is a

image accuracy is required to fabricate prosthetic

flexible, fast, and highly programmable pattern

restorations such as inlays, onlays, copings, andgenerator. Unlike laser line scanners or diffractive

crowns. IOSs simplify clinical procedures for

optical elements (DOEs) with a fixed pattern set, it’sdentists, eliminate the need for plaster models andpossible to program numerous patterns with varying

reduce patient discomfort.

bit depth to a DMD. Structured light solutions
using DLP technology are preferable for moredetailed measurements that require accuracy in themillimeter or even micron range.

Applications leveraging
3D scanning systems
3D AOI
3D automated optical inspection (AOI) is a powerful
technique used in manufacturing settings to provide
real-time, in-line, decisive measurements relating

Figure 4. Dental intra-oral scanner

to part quality. For example, 3D measurements
for PCB solder paste inspection (SPI) are highly

Another example of a growth industry is 3D ear

preferred since they measure the actual volumescanning. Optical imaging systems capture preciseof solder paste deposited before component

3D models of ears rather than using silicon earplacement, helping prevent poor-quality solder

mold impressions. 3D ear scanning also can enable

joints (Figure 3). PCB manufacturing also leverages

the future of customization for consumer earbuds,

3D AOI in-line after component placement, reflow,

hearing aids, and hearing-protection devices.

final inspection, and rework operations to maximize

Industrial metrology and inspection

quality and reliability. As 3D inspection capabilities

There are a multitude of different industrial metrology

become more widespread, there are several

and inspection systems that have migrated to 3D

emerging

optical-scanning techniques.

in-line factory

Figure 3. Illustration of PCB 3D SPI

inspection

Optical 3D surface inspection microscopes arepoints

an example of an alternate option to offline CMM

choosingsystems. These microscopes can measure more

to takefeatures for height, roughness, and computer-aided

advantage

design (CAD) data comparison. Factories that buildof 3D

machined, cast, or stamped goods are another area

AOI systems.

embracing optical inspection. They can more easily

High accuracy 3D scanning using 		
Texas Instruments DLP® technology for structured light3

September 2018

complete details of real-world objects in a 3D data
format (Figure 7). The data can then be used
for product design, part engineering, 3D contentcreation, or as input to a 3D printer. For example,
online retailers can 3D scan their products andpresent them online in a true, high-quality 3D model
instead of 2D pictures. Gamers may 3D scanthemselves and create their own avatars in a game.

Figure 5. Robotic arm with 3D scannerand accurately measure x, y, and z dimensions for
improved quality assurance. Inline 3D vision systems
combined with robot arms have also emerged in themarket (Figure 5). These robotic implemetnations
can greatly increase speed and quality at automotive(Figure 6) and other production-line factories.
Adding 3D inspection at specific stages of theFigure 7. Desktop prosumer 3D scanner

assembly and production process can catch quality
issues early, thereby reducing waste and rework. 3D

3D biometrics identification and authentication

scanning systems can even be implemented insidecomputer numerical controlled (CNC) equipment

The use of biometric identification andand 3D printers to enable real-time measurements

authentication continues to increase. It is often usedduring the manufacturing process.

for securely locking or unlocking devices, security
checks, and financial transactions. Using optical
3D scanning technology to capture face, fingerprint
or iris biometrics can be a more secure means ofidentification and makes hacking and other attacks
more difficult (Figure 8).

Figure 6. 3D structured light scanning for automotive alignment andinspection

Prosumer 3D scanners
Prosumer 3D scanners are portable tools offering
professionals and amateurs the ability to captureHigh accuracy 3D scanning using 		
Texas Instruments DLP® technology for structured light

Figure 8. Fingerprint rendering resulting from a 3D scan

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September 2018

System design benefits when
integrating DLP technology

when designing solutions using DLP technology.
They can also optimize optical architectures tomatch key resolutions and illumination requirements

Whether inspecting PCBs for quality or making

for inspection scans. It is exciting that innovators

an accurate dental fitting, 3D scanning equipment

can take 3D scanning to new levels using advanced

using DLP technology for structured light canprogrammability to optimize performance in all threeoffer several compelling system benefits. Theof the spectral, spatial and temporal domains.

micromirrors on a DMD switch very fast—inmicroseconds—and can enable 8-bit phase shift

DLP Products portfolio
considerations

rates greater than 1,000 patterns per second. This
leads to high-speed data capture rates to achieve

TI’s advanced light control portfolio offers DMDs

real-time 3D scans that are very useful for in-line

and companion controllers imaging capabilities

measurements. High-speed DLP chips also offer

beyond traditional display. In particular, DMD chips

programming flexibility to dynamically select andspan 363-nm to 2,500-nm wavelength range, havereorder patterns on the fly. This helps ensure thebinary pattern rates up to 32 kHz and offer more

optimal pattern is applied to specific object locations

precise pixel accurate control. Here’s how DLP

or within specific fields of view, which assists inchipsets with advanced light control can benefit

extracting the most accurate 3D information forstructured light systems.

analysis. Pattern duration and brightness can becontrolled, ensuring the optimal amount of light is

DMD characteristics

being reflected from the object and maximizing the• Resolution—DMD options range from 0.2

dynamic range from the camera.

to 4.1 megapixels (MP) at the time of thisDLP technology can be combined with various

publication. Larger 1, 2, or 4-MP DMDs tend tolight sources and is compatible across ultraviolet

be used for systems requiring larger scan areas(UV), visible and near-infrared (NIR) wavelengths

or bright ambient light situations. For instance,(Figure 9). This offers additional versatility for

automotive 3D inspection requires large scan

tailoring 3D scanning systems based on the target

areas on bright factory floors during assembly

object’s reflectivity. The flexibility to combine DLP

and alignment process steps. DMDs less thanchips with a broad choice of light sources and

1-MP tend to be placed in compact handheld

diverse camera options makes it possible to easily

or tabletop equipment that requires portability or

create one piece of equipment to measure multiple

low power consumption.

objects. It makes sense that automotive, industrial• Power—The smallest chipsets use less thanand medical companies look to DLP chips when

200-mW of power consumption, making them

designing next-generation 3D scanning equipment.

a good fit for portable or battery-operated

System integrators are able to innovate with flexible

systems. Intra-oral scanning, for example, takes

pattern control and new structured light algorithms

advantage of small DMD form factors withFigure 9. Light spectrum

High accuracy 3D scanning using 		
Texas Instruments DLP® technology for structured light5

September 2018low power consumption for battery-powered

than 1,000 structured light row or column

implementations.

patterns using one-dimensional (1D) encoding(see Figure 10 for example). 1D patterns take

• Wavelength—Users have the ability to adjustcolor and illumination intensity in a DLP

advantage of using a single row or column andtechnology-based system based on an object’s

repeating that row or column across the entire

reflective properties. This is made possible sincearray. Prosumer 3D scanner products often use

a DMD can be combined with various light

1D patterns to help reduce cost and increase

sources, including lamps, light-emitting diodes

scanning speed. More advanced controllers(LEDs) and lasers. There are DMDs optimized

support up to 400 pre-stored 2D full-framefor UV (363–420-nm), visible (400–700-nm),

patterns (see Figure 11 for example), which canand NIR (700–2,500-nm) use. For biometric 3D

be more tailored in x and y depending on thescanning solutions, near-infrared wavelengths

application needs or objects being scanned.

are popular because the scans are not invasive.
UV light is sometimes best for optimizing
metals’ reflective properties. For white lightpatterns, white LED optical engines are a

Figure 11. Examples of 2D patterns

desired power-efficient monochrome solution.
• Pattern accuracy and speed—DLP controllers

Controller characteristics

are designed to display patterns suitable for• Pre-stored patterns—DLP controllers provide

machine vision or digital exposure and support

convenient interfaces for reliable, high-speed

variable high-speed pattern display rates up

DMD control. They support pre-stored

to 32,000 patterns per second with camera

structured light patterns without the need forsynchronization. These pattern rates are

an external video processor to stream patterns.

critical for highly accurate and high-speed 3D

Some DLP controllers can pre-store morescanning systems.
From simple to complex systems, DLP technology
offers customers incredible pattern flexibility when
they design their custom structured light system

Figure 10. Examples of 1D patterns

High accuracy 3D scanning using 		
Texas Instruments DLP® technology for structured lighthardware and algorithms.

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September 2018

DLP Products for 3D scanning
Texas Instruments offers a range of DLP chipsets tosuit different 3D scanning requirements as shown inTable 1 below. For the most current and complete
list of DLP chips, see TI.com/dlp.

Micromirror
array

Array
diagonal

Optimized
wavelength

Controller

Max pattern rate(binary / 8-bits)

High-speed
pre-stored patterndisplay(2D or 1D)

DLP2010854 × 4800.20”

420–700-nm

DLPC3470

2,880-Hz / 360-Hz

1D only

DLP2010NIR

854 × 4800.20”

700–2,500-nm

DLPC3470

2,880-Hz / 360-Hz

1D only

DLP30101280 × 7200.3”

420–700-nm

DLPC3478

2,880-Hz / 360-Hz

1D only

DLP4500

912 × 1140

0.45”

420–700-nm

DLPC350

4,225-Hz / 120-Hz

2D

DLP4500NIR

912 × 1140

0.45”

700–2,500-nm

DLPC350

4,225-Hz / 120-Hz

2D

DLP47101920 × 1080

0.47”

420–700-nm

DLPC3479

1,440-Hz / 120-Hz

1D only

DLP5500

1024 × 768

0.55”

420–700-nm

DLPC200

5,000-Hz / 500-Hz

2DDLP6500

1920 × 1080

0.65”

420–700-nm

DLPC900

9,523-Hz / 1,031-Hz

2DDLP6500

1920 × 1080

0.65”

420–700-nm

DLPC910

11,574-Hz / 1,446-Hz—

DLP7000

1024 × 768

0.7”

400–700-nm

DLPC41032,552-Hz / 4,069-Hz—

DLP7000UV

1024 × 768

0.7”

400–700-nm

DLPC41032,552-Hz / 4,069-Hz—

DLP9000

2560 × 1600

0.9”

400–700-nm

DLPC900

9,523-Hz / 1,031-Hz

2D

DLP9000X

2560 × 1600

0.9”

400–700-nm

DLPC910

14,989-Hz / 1,873-Hz—

DLP9500

1920 × 1080

0.95”

400–700-nm

DLPC410

23,148-Hz / 2,893-Hz—

DLP9500UV

1920 × 1080

0.95”

400–700-nm

DLPC410

23,148-Hz / 2,893-Hz—

DMD

Table 1. DLP chipset portfolio showing helpful 3D scanning specifications

Summarysystems. DLP technology is a predominant
technology choice for 3D scanning and machine

3D scanning using structured light is a desirable

vision solutions due to its tremendous versatility

technique for the expanding markets and use

to customize patterns at very high speeds andcases requiring 3D optical measurement. Texas

its ability to pair with multiple light sources andInstruments offers a diverse portfolio of DLP chips

wavelengths. This versatility also drives customerthat can enable small, integrated scanning enginesinnovation and can push 3D scanning system

in personal electronics up to large, high-resolution

capabilities to new limits.

pattern generators used in industrial inspection

High accuracy 3D scanning using 		
Texas Instruments DLP® technology for structured light7

September 2018

Related websites• Learn more about DLP technology.
• Evaluate DLP technology for 3D scanning withan evaluation module (EVM):• DLP 2010 Light Control EVM.
• DLP 3010 Light Control EVM.
• DLP LightCrafter 4500 EVM.
• DLP LightCrafter 6500 EVM.
• DLP LightCrafter 9000 EVM.
• DLP Discovery 4100 Development Kit.
• Download these reference designs from the TI
Designs reference designs library and speed
product development using DLP technology
schematics, layout files, bill of materials, andtest reports:•	DLP2010: Small Form-factor Structured•	DLP4500: Accurate Point Cloud Generationfor 3D Machine Vision Applications usingDLP Technology.
•	DLP6500: High-Resolution 3D Scanner forFactory Automation using DLP Technology.
• Contact optical design manufacturers (ODMs)
for production-ready optical modules:•	Pico chipsets – buy optical engines.
•	Advanced light control – optics andelectronics.
• Contact design houses for custom solutions:•	Pico chipsets.
•	Design service providers.
• Contact your local TI salesperson or TI
distributor representative.
• Check out the TI E2E™ Community DLPLight Pattern Generator Reference Design

Products Forum to search for solutions, getfor Portable 3D Scanners

help, share knowledge and solve problems withfellow engineers and TI experts.

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