Thermal 3D sensor technology: simulation and validation of metrological limits

• Applicant: Professor Dr. Gunther Notni
• Subject Area: Measurement Systems ; Optics, Quantum Optics and Physics of Atoms, Molecules and Plasmas
• Term: since 2026
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 573664695

The established optical three-dimensional surface detection reaches its limits with transparent, translucent, shiny and black objects. To solve this metrological problem, the applicant developed an active thermal 3D measurement method based on pattern projection in the thermal infrared and the subsequent stereo camera recording of heat patterns. This innovative measurement principle enables a new class of 3D sensors for almost all types of objects with both non-cooperative and cooperative surfaces. Experiments with initial laboratory setups indicate that this metrological approach has enormous potential. In order to evaluate the possibilities and technical limitations, a comprehensive simulation model is being developed and used for extensive investigations with regard to the measurement objects (e.g. heterogeneous materials or structured, more complex geometries), the projection method (e.g. different scanning algorithms or projection patterns) and the components used (e.g. radiation sources or cameras). In this way, possibilities for improvements in terms of the robustness of the process, the measurement time, the quality of the 3D data (structure and shape resolution), the simplification of the sensor technology and the reduction of hardware costs are identified and analysed. Because a large number of fundamentally new concepts have to be investigated, the experimental implementation of which would be too costly and time-consuming, the comprehensive simulation model is indispensable. It promises a fast and well-founded evaluation of a wide range of approaches, for example for 3D measurement of highly dynamic scenes using single-shot infrared projection, for cost reduction by eliminating the camera, or for simultaneous determination of surface shape and material thickness. In addition, it allows virtual investigations of sample integrity in order to increase the acceptance of thermal 3D measurement methods, for example for cultural historical objects or in medical technology.

• DFG Programme: Research Grants