Creation of milling data in GridPhoto.
GridPhoto
is a convenient solution for 2D photo engraving.
Grey scale images are converted from programs using a few
Mouse clicks
into high quality milling data for almost all 3 or 4 axis machine tools. In
GridPhoto,
grey scale images are processed and converted into
dotted or linear milling data. The photos should be available as grey
scale images with 256 colours (exception .JPG). The imported images can be
edited, scaled, filtered, mirrored and very rapidly converted into milling
data.
With milling there results a gridded image
which resembles a photo, for example in a daily newspaper The light/dark
variations (grey scales) in the photo are created through dots or lines
with appropriate intensity or density.
Using Milling data graphics you can
monitor the calculated milling data and, as required, repeat the
calculation with modified settings as often as you wish.
GridPhoto
has available various
grid, dither and hatching processes for the
creation of optimum milling data. In the grid
process grey scales are created through dots with varying diameter and the
same separations (3D milling data). The dither
process creates grey scales through dots with the same diameter and
variable separations (2Dmilling data). With the
hatching process the grey scales are represented through 2D
hatching lines in adjustable directions and separations.
Help
on the functions can be obtained with the activated navigator using <F9>,
in the menu also using [?] and clicking-on the function.
Import photo.
|
Import a grey scale image and adjust dimensions (measurements). The program
imports Bitmap files (256 Grey scales, 8Bitgrey scales, 1Byte/Pixel) in
the following formats:
BMP
|
Windows
Bitmap, 8Bit grey scales.
|
GIF
|
CompuServ
Bitmap, 8Bit grey scales.
|
PCX
|
Paintbrush
Bitmap, 8Bit grey scales.
|
JPG/JPEG
|
JPEG
Bitmap, also 24 colour format.
|
Before
calculation of the milling path a photo should be processed into a
photostyler (e.g. Corel PHOTO-PAINT) and saved as grey scale image
(8Bit/Pixel - not in colour, exception .JPG). Images in the .JPG -
format can also be saved as colour images (24Bit). On import these are
converted into grey scale images.
Gridded photos (e.g. from periodicals) have a very rough
surface and should as far as possible be avoided or reworked in a suitable
photostyler. Gridded images can also be improved
using approximate
fine/strong.
Height
- width ratio (Input in mm):
Proportional
:
|
YES:
|
All axes modified proportionally the same.
|
No:
|
The axes are input individually.
|
|
Dimension X/Y/Z [mm] |
Input of the measurements in mm. |
Modify
frame.
|
Edit the relief limits (clip or expand
relief).
Extract
XY: |
Take over
the area to be framed by a rectangle. |
Add
border: |
Create a
border around the relief.
Border width [mm]: |
Input of the
additional border around the relief. |
Same level [Y/N]: |
YES: |
The relief is
continued outwards around the border using the outermost
level. The subsequent border level input is inactive. |
No: |
The relief is
continued outwards using the value given in 'Border level'. |
|
Border level [mm]: |
Z value for the
border around the relief. This value is only effective with the
setting 'Same level = YES'. Only numbers between minimum and
maximum relief Z values can be entered. Default is the lowest
relief point. |
|
Limit top
/ bottom: |
Limits the
relief in Z (cut off relief top/bottom).
For Z value input first select a suitable (Z) point using the cursor
in relief. The Z level can be corrected to the correct value in the
subsequent input. Only numbers between minimum and maximum relief Z
values can be entered. Following confirmation the relief is
correspondingly limited. |
Scaling.
|
Adjust a relief in size and resolution.

Scaling
%: |
Adjust
measurements in X/Y/Z (input in %). With Proportional = YES all
axes are the same, with No the axes are entered individually. |
Dimensions XYZ: |
Height-Width
ratio (input in mm).
With Proportional = YES all axes are the same, with No
the axes are entered individually. |
Reduction
%: |
Enlarge
image in X/Y remove dots and with this reduce resolution and
amount of data. |
Levels: |
Grey tone
grading, coarsen image in Z. |
Double
resolution: |
Double
resolution of the overall image in X/Y. The position and enlargement
remain unchanged. |
Filter.
|
Revise/smooth the photo. Suitable filters are,
for example, approximate.

Error
pixels: |
Regional filter.
The dot, which deviates from all its neighbouring values by more than
the specified value, is approximated (smoothed). |
Outliers: |
Regional Filter. Delete large deviations to the neighbouring dots. |
Approximate/
approximate heavily: |
The relief
is smoothed. The approximating can, as required, be repeated several
times. |
Smooth: |
The relief
resolution is doubled and the image is, at the same time, lightly
smoothed. This filter gives significantly higher amounts of data and
should therefore be used only for coarse images. Images with too high
a resolution can be reduced again using 'scale . reduce (e.g.: [%] =
50)' |
Radius filter: |
Smooth the
relief, all edges are rounded off. |
Correction filter 1: |
Smooth the
relief, all edges are rounded off on one side. |
Correction filter 2: |
Fill holes (e.g.
after STL import). |
Mirror + rotate.
|
In
the case that it has still not taken place the image can be rotated or
mirrored in all axes. Mirror complete image in X, Y, Z and rotate by
+/-90°.

Mirror
X/Y/Z: |
Mirror image
in X, Y or Z. |
Countershape XZ: |
Simultaneous
mirroring for a countershape in X and Z direction. |
Rotate
+90°/-90°: |
Rotate image
by +90° (counter-clockwise) or -90° (clockwise). |
Line gridding. |
  |
|
Using line gridding grey scale
images are milled using a conical tool in 3D lines. The tool, depending on
image brightness sinks to different depths in the material and thus
creates the photo in the workpiece. Light areas of the image result in
small milling depths and, through the tool cone, small line widths. Dark
areas of the image, on the other hand, result in large milling depths and
wide lines.
With import of the photo the image is converted into a relief. The
measurements X/Y are the dimensions of the photo (reliefs). These ca be
adjusted using
'scaling'. The milling depth is determined by the relief depth (input/modification,
for example using
scaling . dimension Z).
For the engraving of photos no large milling depths are necessary, usually
a few 0.1 mm suffice. The normal procedure is the engraving of the image
and subsequent covering (filling) of the cutter track using colour. With
the employment of multi-layer material the thickness of the upper milling
layer must be noted (set the safety height (Off) higher and incise
slightly deeper).
Display in upper window.
Measurement X/Y [mm]: |
Measurements
of the image and the engraved workpiece. |
Max.
milling depth
Z [mm]: |
Indication
of the tool insertion depth in the material (relief depth). |
Milling
path separation: |
The milling
path separation (separation of the milling lines) is tool radius
multiplied by the line separation (/100%) with max. depth. The
milling path separation is heavily dependent on the tool angle TAn) and
the relief depth. Smaller tool angles or smaller milling depths result
in more milling data. The more lines which are milled the better
effect the image has. But with this the milling time increases. |
Line
number: |
Number of
determined milling lines. |
No. of
layers: |
Calculated
number of layers. If the 'layer depth' is selected >= 'Max. Milling
depth Z', then there is only one milling layer. |
Inputs.
Tool #: |
Selection of
a suitable milling tool.
For milling, conical tools (with cone angle (CAn) >0°, e.g. 20..30°)are
always to be employed. The cutter tip should be selected as small as
possible (CuT <0.1 mm). For small cutter tips always pay attention
to sufficient rpm. |
Line
separation [10..500%]: |
The line
separation is related to the tool radius with max. milling depth (100%).
The milling path separation is determined by the line separation. A
larger line separation results in a larger milling line separation and
an image with a lighter effect. Recommended settings for photo
engraving are 100% .. 300%.
Reliefs (e.g. Lithophane for transmitted light) can be milled using
the program. For this a tool with larger tip radius or spherical
radius and smaller line separation (ca. 10..50%) is to be selected.
With line gridding only a tool offset of the cutter tip is
calculated. We therefore recommend the relief module or the
program eMillRelief for correct relief production. |
Angle
[-90..+90°]: |
Setting of
the angle of the milling lines. 0° produces horizontal lines. |
Procedures: |
Milling method selection:
 |
Hatching:
Simple lines without turnaround. |
|
Cross hatching:
Simple lines without turnaround + 90° rotated crossings. |
 |
Hatching meander:
Lines in zigzag order. |
 |
Cross hatching meander:
Lines in zigzag order + 90° rotated crossings. |
 |
Rectangle:
Rectangles concentrically ordered. |
 |
Circle:
Circles concentrically ordered. |
 |
Spiral:
Elliptical spiral. |
|
Radial lines:
Simple radial lines without turnaround. |
 |
Radial lines meander:
Radial lines in zigzag order. |
 |
Spiral > rectangle:
Elliptical spiral go over to rectangle form. |
|
Layer
depth [mm]: |
Dependent on the
Max. Milling Depth Z the image can be milled in one or more
layers. If the
layer depth is exceeded, the program creates several milling
layers. |
Contrast
[-0.5..+0.5]: |
With values >0 the image is higher-contrast (light and dark grey
scales are reinforced). With values <0 are milled with less contrast. |
Inverse [Y/N]: |
YES: The brightness levels are
inverted. Light areas are milled dark, dark areas are milled light. |
Lines
100% |
Cross-hatching
150% |
Gridding.
|
Using
gridding the grey scales in the image are
created by dots of various diameter and the same separations. The variable dot diameters are created
using a conical tool, which is sunk (inserted)
appropriately deep into the material. Small dot
diameters are achieved through small insertion, large dot diameters
through strong insertion (3D milling data). Conical tools and a 3D machine tool are
demanded for the grid process.
Display in upper window.
Dimensions X/Y [mm]:
|
Dimensions of the image and of the workpiece.
|
Max. milling depth Z [mm]:
|
Indication of the greatest milling depth (for black dot) in the material. The max. milling depth results from
the dot separation and the tool angle.
|
Number of dots X/Y/total number of dots:
|
Possible number of dots if all dots in the lines are milled.
At 'white' points in the image no dots are milled. Please not the indication of the number of dots during the
input. The milling time (ca. 1-4 dots/sec)
can be estimated easily using the number of dots.
|
Inputs.
Tool tip radius [mm]:
|
Smaller
dot separations and a greater total number of dots can be achieved
using a small tip radius. The tip radius should be selected as small as
possible (finest grid dot).
|
Tool angle[°]:
|
Conical tools are required for
gridding. Convenient tool angles
lie at 40..49°. Smaller tool angles increase the milling depth.
|
Safety height
(SH) [mm]:
|
Safety
clearance of the cutter tip to the surface of the material for
withdrawn movements. The smaller the
safety height is chosen the more dots can be milled at the same time.
|
Processes:
|
Milling processes for the image.
Vertical:
|
Each dot is milled vertically
from the safety height into the material (long movements).
|
Inclined from
Mat.:
|
The dots are milled into the material inclined along the tool
angle. Up to the next dot an
inclined movement takes place up to the material surface (short
3D movements).
|
Lines:
|
The individual milling depths are connected together by lines
so that milled lines of different depth and thus different
stroke widths result (short
3D movements).
|
Inclined from SH:
|
The dots are milled inclined along the tool angle into the
material. Up to the next dot an
inclined movement up to the safety height takes place
(long 3D movements).
|
|
Dot separation [mm]:
|
Separation of the grid points. The dot separation must be selected at least 4 x
Tool tip
radius, otherwise no contrast
is possible within the image. The
greater the ratio Dot separation/
Tool tip radius is selected, the more
contrast is possible in the milled image.
|
Density value:
|
A density value
< 0 results in a lighter image after the engraving.
|
Example for dot grid. |
Example for line grid. |
Dithering.
|
New process from Ver. 7.022
The dither process creates the grey scales in the image through dots with the
same diameter but variable separations (2D
milling data). Cylindrical or conical tools can
be employed for the
dither process. A 2D (2.5D) machine tool suffices for the milling processing.
The
dither milling data can, in a wide range, be matched to the job definition. An image milled using the dither
process is effective from a minimum viewing separation. A
sufficiently large image should also be milled.
The program offers 3 milling processes: Dithering 9p,
Dithering 16p and Dithering 25p. Dithering 25p should
be used for large area images only, Dithering 9p is
suitable for rather smaller images.
To
test a suitable milling image select Settings (see below) and Start. You can repeat the calculation
using changed settings as often as you like. For a rapid graphic set the Milling
data aspect to
Milling point
Through the relatively large-area dither dots the dimensions of the
graphic cannot be adhered to exactly. The deviation of the milled image
is visible in the graphic.
Display in the upper window.
Dimensions X/Y [mm]:
|
Dimensions of the image and of the workpiece.
|
Max.
milling depth
Z [mm]:
|
Indication of the tool inserted (sunk) depth in the material.
|
Number of columns X / lines
Y:
|
Possible number of the dither dots if all dots are milled in the
lines. No dots are milled at 'white' points in the image, a dither dot consists, depending on
the process, of several (up to 9, 16, 25) 2D
dots.
|
Inputs.
Tool tip radius [mm]:
|
Smaller dot separations and a greater total dot number are achieved
using a small tip radius. The tip
radius should be selected as small as possible for a high
image resolution.
|
Tool angle[°]:
|
Cylindrical [0°] and conical tools [>0°]
are employed for dithering. Convenient
tool angle lies at 10..20°.
|
Safety
height (SH) [mm]:
|
Safety
height of the cutter tip to the material surface for withdrawn
movements. The smaller the safety height
is selected the shorter is insertion (sink) movement and the
more dots can be milled at the same time.
|
Inserted (sunk) depth [mm]:
|
Milling depth of the tool measured from the tool tip to the surface
of the material.
|
Density [-0.5..+0.5]:
|
Change the milling dot density. With
values <0 the dots are more dense, with
values >0 are wider displaced.
|
Spread
[0..1]:
|
Spread of the individual dots. With the
setting 0 the dots are placed at regular intervals (best
quality). Using larger settings the dots are dispersed. A spread
results in a small reduction in quality. The image appears somewhat
washed out/blurred.
|
Brightness [-0.5..+0.5]:
|
With values >0 the image is milled lighter,
with values <0 milled darker.
|
Contrast
[-0.5..+0.5]:
|
With >0
the image is milled with higher contrast,
with values <0 with less contrast.
|
Inverse [Y/N]:
|
YES |
The brightness
level is inverted. |
No |
Brightness
distribution as in the model. |
|
Processes:
|
Dither milling processes for the image.
Dithering 9p:
|
For rather smaller images with reduced grey scale intensity.
For 1 dither dot 0(white)
.. 9(black) individual dots
are milled (fine resolution).
|
Dithering 16p:
|
For medium-sized image sizes with sufficient grey scale
intensity. For 1 dither dot 0(white)
.. 16(black) individual dots
are milled (medium resolution).
|
Dithering 25p:
|
For larger images with many grey scales. For 1 dither dot
0(white) .. 25(black) individual dots are milled (coarse
resolution).
|
|

Comparison of the dither
processes. From
left to right 9p, 16p
and 25p.
Above spread 0,
below
spread 0,5.
 |
 |
Same image as above but double dimensions
and brightness + contrast
respectively 0.1.
Setting s. image.
Milling data view setting Relief view.
|
Hatching.
|
Convert grey scale image into hatched image.
For this the grey scale number is reduced and the individual level
replaced by hatching so
that a gridded image results. For an as high as
possible contrast result a photo should be
processed in a photostyler
beforehand.
Here, disruptive elements should be removed and a stronger contrast
selected. For
the
hatching a tool must be determined whose tip is to be selected as fine as
possible (Cutter tip [CuT] 0.05..0.1mm).
The hatching separations are determined automatically using the cutter
tips, the grey level and the following settings.
Hatching levels
[1..32]:
|
A grey level image (256 levels)
is reduced to 1..32 hatching levels.
Sensible are 4..32 hatching
levels.
|
Density
[-20..100%]:
|
Change hatching density (line
separation). The effect corresponds with
the contrast setting. Values < 0
reduce the contrast, values > 0 raises the contrast.
|
Brightness
[-20..100%]:
|
Change hatching separation for all hatching levels
uniformly. The
effect corresponds with a brightness setting.
|
Hatching contour separation [0..100%]:
|
Determines the safety separation of the milling tracks in the
milling direction to the contour (track). With
the selection Combine hatching lines =
YES this value must be > 0
and lie at ca. 50% (>10% .. 70%).
|
Hatching angle [-2,-1.0..180°]:
|
-2
|
The hatching angle is
automatically set for each layer with increasing value.
|
-1
|
The hatching angle is
automatically set for each layer with increasing value and
alternatively displaced by ca.90°.
|
0..180
|
The hatching angle is set for all
angles at the specified value.
|
|
hatching directions [1..6]:
|
1
|
Hatching lines in set direction
only.
|
2
|
Hatching lines in set direction,
displaced + 90°.
|
3
|
Hatching lines in set direction
displaced + 60°
and 120°.
|
etc.
|
Join hatching lines [Y/N]:
|
YES:
The hatching lines are joined together.
|
Add hatching contours [Y/N]:
|
Yes:
Save the hatching limits to the created paths.
|
Tool input for hatching.
For the creation of milling data complete tool information is required. The tool data are entered in the tool
list. The tool list
can be reached with Tool Input.
 |
This
setting of the milling data view is employed if milling data has been
calculated using gridding, dithering or hatching.
The black
indicated form of view is set. The forms of view in
blue
can be selected. |
Milling
point: |
Drawing of the
milled image in plan view with filled cutter
trace (cutter simulation,
rapid display). |
Relief
view: |
From the
milling paths a relief (3D form)
is calculated and drawn in grey scale image (slow
display due to the high computing time). |
Render
view: |
A rendered image is calculated from the milling paths
and is displayed (slow display due to high computing time). |
Relief
colour: |
Representation
of the relief
and
render
view.
Standard: |
Standard
grey values. The background is white,
milling points are presented dark. |
Inverse: |
Inverse
grey values. The background is black,
milling points are presented light. |
|
Milling data
graphics.
|

|
Drawing of the milled image in plan view
with filled cutter trace (cutter simulation).
|
Milling data > Layer.
(Only
for CAD/CAM complete
system)
|
Take over the
milling data in a graphic layer.
Milling data export.
|
Following calculation, the milling paths can be exported in various formats.
Navigator.
|

|
In
the
Navigator the most important program functions are
summarised in the correct processing order.
The Navigator leads you through the processing. Processing takes place from
top to bottom. You can select the function marked in black.
If a function is not to be selected then, using next
you switch to the next operation.
Using back
you switch to the previous function.
|
Open
(Import photo):
|
Import a grey scale image and adjust the dimensions (measurements).
|
Filter:
|
Rework/smooth (finish) the image.
Suitable filters are, for example, approximate.
|
Mirror+rotate:
|
In the case that it has still not taken place, the image can be
rotated or mirrored in all axes.
|
Raster photo:
|
Gridding.
|
With
Gridding the grey scales are
created in the image through dots with different diameters and
the same separations.
|
Dithering.
|
The
Dither processes create the grey scales in the
image through dots with the same diameters and variable
separations (2D milling data).
|
Hatching.
|
Convert grey scale image into hatched image.
For this the grey scale number is
reduced and the individual levels is replaced by hatching so
that a gridded image results.
|
|
Milling data export:
|
Following calculation the milling paths can be exported in various
formats.
|
End
Navigator:
|
Program
operation without Navigator. Now all menu
functions are available. For operation please follow the program
help [?] or
<F9> and click-on the
function.
|
|