Using a Digital Twin for Fringe Projection Profilometry Optimisation

Fringe projection profilometry (FPP) is a widely used technique for measuring object surface form and three-dimensional (3D) geometry, capable of delivering high-precision, high-resolution measurements when paired with suitable cameras and projectors. However, in practical deployments, identifying parameter configurations that maximise precision while satisfying real-world constraints remains challenging. To address this, we present an automated digital twin framework implemented in Blender, an open-source 3D software package that provides a ray-traced rendering environment that enables accurate simulation of physical systems. We replicated the physical setup in our digital twin by matching characterisation quality, gamma response, and characterisation images. Accurate system characterisation using Zhang's method [1], to obtain intrinsic and extrinsic parameters, is shown to be critical for achieving high precision. Using this digital twin, we then demonstrate systematic exploration and optimisation of key parameters, including phase-shift count, camera-projector spacing, and fringe density. These parameters span both system geometry (e.g. camera-projector positioning) and algorithmic choices, such as 2D phase-shifting and unwrapping methods [2]. Three measurement artefacts, representative of real world metrology scenarios, were used to benchmark the system. The symmetrical mean Chamfer distance (SMCD), computed between ground-truth and reconstructed meshes, was used to evaluate reconstruction quality. After optimisation within the digital twin, transferring the optimal parameters to the physical system reduced the number of required images per measurement by 48% (from 36 to 21). A reduction of 74.0% mean SMCD was also achieved for fringe pattern stripe count alteration. A 36.9% mean SMCD was obtained for adjusting the camera and projector spacing purely in the digital-twin.