The Alphatype CRS ("Cathode Ray Setter") was nominally 5333dpi, but it's a bit of a fudge. As the person who wrote the DVI interface for it, and personally ran the entire Art of Computer Programming, Vol. 2, 2nd Edition through it, let me explain.

You are very correct that in the early 1980's, even 64k of RAM was quite expensive, and enough memory to handle a complete frame buffer at even 1000dpi would be prohibitive. The Alphatype dealt with this by representing fonts in an outline format handled directly by special hardware. In particular, it had an S100 backplane (typical for microcomputers in the day) into which was plugged a CPU card (an 8088, I think), a RAM card (64k or less), and four special-purpose cards, each of which knew how to take a character outline, trace through it, and generate a single vertical slice of bits of the character's bitmap.

A bit more about the physical machine, to understand how things fit together: It was about the size and shape of a large clothes washer. Inside, on the bottom, was a CRT sitting on its back side, facing up. There was a mirror and lens mounted above it, on a gimbal system that could move it left/right and up/down via stepper motors (kind of like modern Coke machines that pick a bottle from the row/column you select and bring it to the dispenser area). And, at the back, there was a slot in which you'd place a big sheet of photo paper (maybe 3ft by 3ft) that would hang vertically.

OK, we're all set to go. With the paper in, the lens gets moved so that it's focused on the very top left of the paper, and the horizontal stepper motor, under control of the CPU, starts moving it rightwards. Simultaneously, the CPU tells the first decoder card to DMA the outline info for the first character on the page, and to get the first vertical slice ready. When the stepper motor says it's gotten to the right spot, the CPU tells the decoder card to send its vertical slice to the CRT, which flashes it, and thus exposes the photo paper. In the meantime, the CPU has told the second card to get ready with the second vertical slice, so that there can be a bit of double-buffering, with one slice ready to flash while the next one is being computed. When the continuously-moving horizontal stepper gives the word, the second slice is flashed, and so on. (Why two more outline cards? Well, there might be a kern between characters that slightly overlaps them (think "VA"), and the whole thing is so slow we don't want to need a second pass, so actually two cards might flash at once, one with the last slice or two of the "V" and the other with the fist slice of the "A".)

So, once a line is completed, the vertical stepper motor moves the lens down the page to the next baseline, and then the second line starts, this time right-to-left, to double throughput. But therein lies the first fallacy of the 5333dpi resolution: There is enough hysteresis in the worm gear drive that you don't really know where you are to 1/5333 of an inch. The system relies on the fact that nobody notices that alternate lines are slightly misaligned horizontally (which also makes it all the more important that you don't have to make a second pass to handle overlapping kerned characters; there it might be noticeable).

Looking closer at the CRT and lens, basically the height of the CRT (~1200 pixels, IIRC) get reduced onto the photo paper to a maximum font size of ~18pt (IIRC), or 1/4in, giving a nominal resolution of ~5000dpi on the paper. But this design means you can't typeset a character that was taller than a certain size without breaking it into vertical pieces, and setting them on separate baseline passes. Because of the hysteresis mentioned above, we had to make sure all split-up characters were only exposed on left-to-right passes, thus slowing things down. Even then, though, you could see that the pieces still didn't quite line up, and also suffered from some effects of the lack of sharpness of the entire optical system. You can actually see this in the published 2nd edition of Vol 2.

Finishing up, once the sheet was done (six pages fit for Knuth's books, three across and two down), the system would pause, and the operator remove the photo paper, start it through the chemical developer, load another sheet, and push the button to continue the typesetting.

It's worth noting that the firmware that ran on the 8088 as supplied by Alphatype was not up to the job of handling dynamically downloaded Metafont characters, so Knuth re-wrote it from scratch. We're talking 7 simultaneous levels of interrupt (4 outline cards, 2 stepper motors that you had to accelerate properly and then keep going at a constant rate, and the RS-232 input coming from the DEC-20 mainframe with its own protocol). In assembly code. With the only debugging being from a 4x4 keyboard ("0-9 A-F") and a 16 character display. Fun times!

Now, if anybody asks, I can describe the replacement Autologic APS-5 that we replaced it with for the next volume. Teaser: Lower nominal resolution, but much nicer final images. No microcode required, but sent actual bitmaps, slowly but surely, and we were only able to do it because they accidentally sent a manual that specified the secret run-length encoding scheme.