Adding a few more things, I spent several months doing competitive analysis of DLP chips when I worked at Hewlett Packard. The torsion hinge is not silicon but a titanium/aluminum alloy. Lots of interesting material properties of Ti/Al I won't get into here. The most important thing missing from the narrative is that this device was the first truly micro electro-mechanical device. I say that because it is not just electrostatics that are responsible for the mirror motion. If you look carefully at the SEM images, you will see that, under the mirrors, there 4 little tabs attached to the posts. These are actually tiny springs. When a mirror is flipped to one side, the electrical force holds it down. What is really interesting here is that when it is time to flip the mirror, a short voltage spike is applied to the "down" side. This pulls the mirror down on these little springs then lets it go. The result is a very fast flip to the other side where there is a voltage applied to hold it there until it is time to flip it the other way. If you are wondering why it is this way, think about the inverse square law. On the down side, the mirror is about 100 nanometers from the electrode. On the up side, the mirror is a couple of microns from the electrode. The force on the down side is hundreds of times that of the up side. It will flip by pulling from the up side but it will be way too slow for a video projector. Pull down really hard for a microsecond then let go and the mirror flips really fast! Pretty cool technology from TI. Note that Hewlett Packard didn't ever produce a projection chip. They spent a lots of millions and couldn't come up with something that could do better that the DLP chip. But, that's another story...
that's fascinating! the stronger force available is in the wrong direction, so use that to pull it against a spring and then let go... clever. I just assumed that they used the piezo effect to move the mirrors. Any short explanation as to prefering electrostatic?
Am I the only one thinking "holy shit we are able to create and assemble mechanically moving objects so small that you need an SEM to look at them" ? That is amazing. Sure nobody bats an eye anymore at 22nm processors but.. We're talking actually mechanically moving things
I agree. It is pretty amazing. What's even more amazing is that we use devices with this kind of complexity every day, and don't bat an eye. Or the fact that you can buy a chip made using this super complex and mega-expensive-to-develop manufacturing technology for literally .1$ a pop. It won't be a very interesting IC chip, but, doesn't mean it's not amazing that it exists and is sold for basically nothing!
Not only do you need powerful microscopes to look at some of these mechanical system, but we have even brought down mechanical systems to the point where their vibrational modes need to be treated quantum mechanically. See eg k-lab.epfl.ch/page-102900-en.html
***** There is an effort underway to make a Babbage engine about 1 cm on a side. Why? Parts that tiny can run at millions of operations a second. A Babbage machine can do a lot in a single clock cycle.
+Cooking With Cows I'm totally amazed too. I was hoping he would go into the other method of getting all the colours. Same principlal with the mirrors but there are 3 light sources pointing from different angles. So the mirrors have to move in more directions, even more tiny moving parts.
I work on cinema projectors for a living. Those 3 DMD chip light engines are super fascinating and make up the majority of modern day cinema projectors. Single DMD chips are cool to with the color wheel they instead of the prisms.
Just so you know i was lurking through internet at 3:00 am in the morning, found this video and decided to watch it instead of sleeping ! nice video and keep them coming !
This is a necessary video because other videos tend to emphasize CGI and theory. However, this is one of those technological subjects where the old fashioned approach works best. Great video and thanks for your hard work.
This was the best video on DLP projector technology I've seen. I love your channel. You could have made a simple color wheel to explain the secret sauce: the timing between the DMD and the wheel, but even without that, this video was excellent. Thanks!
I'd just like to say that I have been watching your videos for about a year or so now and they are amazing little lessons into your line of work and expertise. I believe the quality of the "lessons" have improved greatly and I am eager to see how this evolves in the future.
Thanks! I really appreciate your comment. Practice certainly makes it easier for me to make better videos. I've deliberated whether adding higher production value items (intro/outro, clickable links, animations, voice-overs, better shot setup, etc) would be worthwhile. I think that many folks watch my content because the videos are clear, but do not have any high production value features. They are also free of BS, rambling, paid placement, etc. On the other hand, I do wish that I could show certain concepts with animations that are more illustrative than my drawings. Let me know what your thoughts are.
Applied Science I am part of the audience that appreciates the clarity, lack of paid placement and lack of rambling (although I think rambling can build a type of ethos similar to Q&A at the cost of clarity). I would not trade any of these "virtues" for animations (your paper ones are pretty good). I think links improve the quality of the lesson and increase chances of people watching other videos of yours and give us an idea of the sources you use. I think you already have great shot setup, voice-over and outro. I think the fact that you respond to a high number of comments is also very admirable and enhances your educational value. This channel is a great example for TH-cam education. I too am interested in the future of education and will certainly look to your channel when I finish my current schooling (PhD microbiology... I love the SEM pictures you take. I'm currently using one for my research and it is how I found your channel in the first place :D) as an example of how I might set up my own TH-cam content. Thanks again!
just replaced the DLP chip in my Mitsubishi. Super interesting to see in 'innards'. Off to see how they manufacture it now. Amazing to be able to work in such small detail.
As a kid we got a tour of a movie theater. They said that there are thousands of mirrors. I thought that they meant they were layered on top of each other. This is cool to see it under microscope, it makes way more since now.
Whoa, this was way more amazing than I thought. Thank you so much for detailed and well presented video. Seeing the actual physical item is so much amazing than an animation. I just cannot imagine how much work has been put into the manufacturing process of this. The engineers that started this idea must've been extremely ambiguous to make this concept a reality. I can hardly even believe it.
for some reason this is even more amazing to me than a microprocessor, how do you make a mirror that small, how do you make that something mechanical this small operate reliably, probably millions of DLP projectors that have been running for 20 years now still out there still working.
Interesting video, Ben. It would be cool to see your macro-DLP in action. It'd also be cool to see the area in the projector that the mirrors reflect light to when not sending it to the lens - a negative I guess.
The first HDTV I ever owned was a Samsung DLP set... It was one of the earliest DLP TV sets, and it suffered from major design-flaws in the "light-tunnel" and the color wheel. The "light-tunnel" was, quite literally, a tunnel lined with mirrors that was supposed to channel light straight into the DLP chip. Stupidly, they designed it such that every *other* mirror in the tunnel was held in place with glue, and the ones that weren't held in place with glue were held in place by friction from their neighboring mirrors. So, eventually, the mirrors dropped off the sides of the "light-tunnel" and reduced the amount of light reaching the DLP chip. The color-wheel was the 2nd problem -- it used a stepper-motor to "align" the colors with the DLP chip, which was completely ridiculous -- all it took to screw that up was one little glitch in the stepper-motor, and suddenly the colors weren't aligned properly with the picture that the DLP chip was displaying, so everything looked like a rainbow. After 3 years or so, the set was so badly compromised, that I had to toss it out and buy a new TV. Really ticked me off, too, because when it was brand-new it had a picture that was far better than any LCD or Plasma set of its day. I wish they had designed that set better.
Wow!! I took apart one of DLP-s and I found this chip, and I didn't know how this thing works without polarisation. I thought that is a normal LCD chip with mirror behind. Thank you very much for this insight! I can't believe that this projector is actually mechanical! Good work Ben, I'm looking forward to more awesome videos! Take care! :)
Cool, thanks. I knew most of the theory, but what your videos add is always the hands-on part, actually seeing the real stuff. The missing link between theory and practice.
I always wondered what kind of "pixel" projectors used! But when I see the electron microscope image, now I wonder how on earth that can be manufactured. such tiny machinery...
I love this . DLP is working like an early color tv that used a black & white CRT and a drum that would spin a set of red green and blue film filters in front of the picture tube to create a color image. The picture tube was qued by a sensor so that the corect brightness level would be presented on the CRT to correspond to the colored film in front of it . This design was abandoned due to the larg drum spinning at 60 revolutions per second being a serious hazard if it were to break while in operation. You could still build a demo model from an old b&w tv .That would be cool to see.
My electromagnetics professor worked for TI and did RnD for the DMD. He gave two lectures explaining the math behind the forces of the torsion spring and the 'capacitor' (gap between mirror-plate and electrode). The steady state relationship between the force of the torsion spring and the force between the two plates of the capacitor relative to the change in distance between the plates of the capacitor with only one intersection where the forces are equivalent, yields an astounding simplification where all variables (voltage, area of plates, spring constant) except one cancel out, leaving only the distance between the capacitor, d/3. The d/3 represents the steady position held when the mirror is 'turned on'. When the force of the spring is equivalent to the force of the mirrors electrostatic attraction to the electrode. Which can then be calculated into the angle at which light is reflected from the mirror ... and thereby all of the mirrors in the array. Another elegant simplification for a boundary of the laws of physics, all because we want to watch cool movies on bigger screens. physicstasks.eu/3250/capacitor-with-plate-on-a-spring#:~:text=Air%20capacitor%20consists%20of%20two,down%20(the%20plates%20remain%20parallel.
Thank you for the extremely well thought out presentation concerning the T.I. DSL properties and complete explanation of that proprietary system. I have a pico-projector that implements the DSL and I have always wondered why I would catch a glimpse of the RGB in their singular state when walking by the projector or moving my head/eyes just right. That is one hell of a system and can only imagine how smart the individual is that was able to put it all together and have it work so well.....thanks again!
Its one of the best channels on YT Man ! Tons of knowledge for free and a good quality one - in depth and interesting. One of the rare internet treasures - I think I will back it up form my children.
Good question. Yes, the chip is made by a photolithographic process, just like silicon integrated circuits. The mirror itself is made by depositing a relatively thick layer of aluminum, then etching away all of the metal between mirrors. The process will also likely require a dissolvable support material that holds the aluminum layer at the correct height, then is washed away to allow the mirror to pivot freely. I'm not sure if the DMD chip is evacuated or has an inert gas charge -- probably vacuum.
I'd like to add that often a process called MEMS "machining" (Microelectromechanical Systems) is employed nowadays in which layers are added and removed using various processes such as lithography, electron beam etching, and vapor deposition (among many many other). MEMS technology is extremely useful for manufacturing micro scale mechanical systems including gears, springs, etc. If you do a google search for "MEMS gear" there's a cool image of a spider mite sitting on top of a rack and opinion made through MEMS processes. This is also the same technology used to make digital accelerometers and gyroscopes used in everything from cell phones to F22 raptors.
Superb and excellent way to make people like me understand about the mechanisms behind DLP projection. Hats off to you for the hard work done by u to build this working mirror mechanism it’s amazing … Thanks for sharing this complex knowledge behind DLP Chip …👏
Nice video. Every time I think about DLP and moving mirrors I think about the sound they make. But well, they move so fast, and they are only 10um in size that I do not think they make any real sound... I think having macro-DLP working would be cool. Even monochromatic one!
A lot of LCD projectors use a spinning color wheel with RGB filters and a monochrome LCD to generate alternating RGB sub-frames in sync with the color wheel presenting the appropriate color filter in the path of the light.
a few instrument makers have also used DMDs to provide a variable geometry input to a spectrograph, so spectra from various parts of the focal plane of a telescope can be taken simply by switching those DMD mirrors to send the light to the spectrograph input.
It's really interesting how these projectors combine the high-tech DMD chip with the low-tech spinning color wheel. I was browsing through old Popular Mechanics magazines and the 1950 January issue was describing a color wheel TV attachment proposed by CBS as a possible way to upgrade a black-and-white set into a color set. The idea was the same as the one behind the DLP projector - have the color wheel in front of a black-and-white CRT and show red, green and blue frames fast enough for them to blend into a color image.
Very well explained i have just purchased a DLP HD projector and am amazed that one bulb can create such an amazing picture and wanted to know how and now I do thanks grate video.
Very cool, I never thought about the binary nature of DLP's and how to get variable brightness from them, thank's for the info. It's funny you put this out today, I just mentioned the rainbow effect you get from DLP like illumination in LED flat bed scanners in my last video but I filmed it months ago.
I have one of the very early generation of DLP flat screen projection tv's, it is a 30" standard def tv with 3 separate projectors, a red blue and green one with separate DLP chip's that lay there image ontop of eachother, before they had started using color wheel's. It was enormous and weighed nearly 200 LB's but quite fun to take apart. There are some newer LED projectors that use RGB LED array's for the light source so they do not need a color wheel and help with any noticeable color separation
If you make the suspension system for your macro-mirror device bistable you need only provide a current pulse to change its state, like a flip-disk display. Radial pre-wound chokes are probably an easy option for actuation.
Come to think of it, just buying a flip-disk display, and adding a mirror to each white pixel sounds like the easiest way. I wonder what interesting things we could make with a huge (1m square) mirror array. Hmmm.
The DMD itself is actually bistable, a large differential voltage is applied to set the mirror state then both left and right electrodes are biased to a constant voltage, so the mirror stays near the electrode it's closest to due to the stronger attraction.
***** Basically the mirrors are pulled so that they reflect the light away from the lens so that it stays within the projector instead of going onto the screen. Also, nice seeing you around here! I have watched many of your videos!
Awesome video, very cool. I'm surprised you don't have more subscribers. Your videos are some of the most interesting and informative videos on TH-cam.
You said the hinge is made of Silicon, but it is actually made of a metal. I've more commonly heard it made of TiAl (Titanium Aluminide). Cool video :) Would have been very excited to see the Macro scale DLP project! Now i want to build something like it!
A couple points: Principal advantage to DLP is that the wasted light is wasted to a separate heat sink, NOT near the electronic device. Also, there are ways to avoid the need for the polarizing film, at least prior to the LCD, and reduce the light loss, using the mirrors or prisms to do the job via reflection, and using the pass through light at the next stage. But, it is pretty much not possible to avoid wasting at least half the light aside from modulation. Many projectors waste much more, in the interest of reducing the cost of the optics.
Great video, you forgot to mention that because the losses are much lower, DLP projectors don't heat up as much as LCD ones and are therefore potentially quieter.
Really enjoyed watching every second of this! It’s amazing what these DLP chips do. That Dell projector was my first DLP! It’s fascinating the similarities to camera sensors and I wonder why they don’t use tiny color filters over slightly smaller mirrors to actually make individual RGB pixels instead of using a color wheel. Our current projector does 3D and it’s interesting how that work as these tiny mirrors are in sync with the shutter glasses. Sometimes I do see the rainbow effect from the color wheel but it doesn’t bother me much. 😄
Old post but wanted to let you know my 2004 Samsung dlp hlp5063w is 14 years old and my Philips square lamp has 14000 hours on it which I'm going to replace soon due to dimming. I replaced the ball bearing color wheel with an air bearing and lubed the fans in 2010. I modified a small square exhaust fan and placed it on the back vent. Picture still looks awesome with my Dish satellite receiver. My next TV is gonna be an LG OLED.
+funky3ddy Yes, a laser projector can produce high brightness and high contrast but there is one problem that is hard to get around and that is safety. As long as the laser beam is moving it's not a problem but what about when the software crashes and the laser spot stops moving? Someone will eventually look directly into the lens of the projector and fry their retina. No company will risk million dollar lawsuits from people with permanent black spots in their vision.
I just recently learned that at least one company is using DLPs to do inexpensive photolithography... that sounds to me like the sort of project you might like to take a stab at, eh? I'd love to see that! I was looking into methods by which a person might do some DIY microprocessor construction aside from FPGA.
You can have the same 3x DMD projector as the 3x LCD one (more expensive). You can also use the same color wheel method if you want with single LCD. There is also a LCoS that is an LCD with a mirror at the back usually also used as a single device in inexpensive projectors. Color LED's have mostly replaced the color wheel wince you can switch fast each color LED and you do not need the color wheel that was way less efficient. You actually need the same amount of light from the light source in a single DMD (DLP) and a 3X LCD since the mirror is mostly away from the light source so the average light output from the projector is lower. Say you want to display RED with DLP (you will need to wait for the RED part of the color wheel usually a quarter of is size so just a quarter of the time the mirror will reflect the light outside the projector and that is only for the part of the light source since just the red part of the spectrum will go trough). On a 3LCD projector the RED part of the spectrum will go trough one of the 3x LCD's but for the full period not just 1/4. Some years ago I used to play with old projectors and replace the original lamp with white LED's (that was before LED projector got popular). I got about 25lumen to 30lumen from a single 6W white LED with 3x LCD projectors. I prefer 3xLCD the most since each pixel has his color there are no color sub-pixels as on monitors so you can have a yellow pixel. And also there is no flicker or that rainbow effect you get with a single DMD or single LCoS.
The damage done by the tweezers makes it obvious why it was originally in that protective case. It would make cleaning the assembly many times easier too since all the fragile parts are inside and all you would have to do is wipe the glass.
Hi Ben you explain in a wonderful way.... I just wonder how do they create, and fix such tiny mirrors and the hinges mechanism in the DLP production factory !!!
The lens that makes it so the light doesn't spread out (uniform irradiance) isn't a biconvex lens like you've drawn, it's a fly's eye lens, which is a microlens array that captures light from many different perspectives and focuses it on a fixed area
DLP is fine for projecting things like PowerPoint slides and other static images. The problem is with action subjects. When "Band of Brothers" was released on DVD, my friends and I watched a couple episodes each week and used a DLP projector on a portable DaLite movie screen. The high contrast, fast action sequences of World War II in the video caused such color separation that I could barely stand to watch it. Some of the guys saw it, others didn't.
I would have thought this idea to be ridiculous. I am impressed by those who made it work. Reminds me of a Mohammed Ali quote : "Impossible is not a fact. It is an opinion."
I love learning about this stuff. Makes everyday life more exciting knowing what kind of amazing tech is around you. Does anyone have any sources explaining how this is manufactured? Or anything on this scale, really? I've never learned how such microscopic products are massively produced.
You explained that in a very easy to understand manner, the model you made is probably how they came across the dmd development. I got a led DLP projector, would that have a colour wheel or a RGB LED that does the colour work? I'm guessing the latter but don't want to dismantle it.
People like you are what make the internet great
Correct!👍
100%
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Adding a few more things, I spent several months doing competitive analysis of DLP chips when I worked at Hewlett Packard. The torsion hinge is not silicon but a titanium/aluminum alloy. Lots of interesting material properties of Ti/Al I won't get into here.
The most important thing missing from the narrative is that this device was the first truly micro electro-mechanical device. I say that because it is not just electrostatics that are responsible for the mirror motion. If you look carefully at the SEM images, you will see that, under the mirrors, there 4 little tabs attached to the posts. These are actually tiny springs. When a mirror is flipped to one side, the electrical force holds it down. What is really interesting here is that when it is time to flip the mirror, a short voltage spike is applied to the "down" side. This pulls the mirror down on these little springs then lets it go. The result is a very fast flip to the other side where there is a voltage applied to hold it there until it is time to flip it the other way.
If you are wondering why it is this way, think about the inverse square law. On the down side, the mirror is about 100 nanometers from the electrode. On the up side, the mirror is a couple of microns from the electrode. The force on the down side is hundreds of times that of the up side. It will flip by pulling from the up side but it will be way too slow for a video projector. Pull down really hard for a microsecond then let go and the mirror flips really fast! Pretty cool technology from TI.
Note that Hewlett Packard didn't ever produce a projection chip. They spent a lots of millions and couldn't come up with something that could do better that the DLP chip. But, that's another story...
that's fascinating! the stronger force available is in the wrong direction, so use that to pull it against a spring and then let go... clever. I just assumed that they used the piezo effect to move the mirrors. Any short explanation as to prefering electrostatic?
cool
wow how can you make something so small and perfect?. if we can make tech that small then whats keeping us from making nanobots?
Very interesting info. Thanks !
I worked on DMD for about 12 years.
Am I the only one thinking "holy shit we are able to create and assemble mechanically moving objects so small that you need an SEM to look at them" ?
That is amazing. Sure nobody bats an eye anymore at 22nm processors but.. We're talking actually mechanically moving things
I agree. It is pretty amazing. What's even more amazing is that we use devices with this kind of complexity every day, and don't bat an eye. Or the fact that you can buy a chip made using this super complex and mega-expensive-to-develop manufacturing technology for literally .1$ a pop.
It won't be a very interesting IC chip, but, doesn't mean it's not amazing that it exists and is sold for basically nothing!
Not only do you need powerful microscopes to look at some of these mechanical system, but we have even brought down mechanical systems to the point where their vibrational modes need to be treated quantum mechanically. See eg k-lab.epfl.ch/page-102900-en.html
MEMS (Micro Electromechanical Systems)
en.wikipedia.org/wiki/Microelectromechanical_systems
NEMS (Nano Electromechanical Systems)
en.wikipedia.org/wiki/Nanoelectromechanical_systems
***** There is an effort underway to make a Babbage engine about 1 cm on a side. Why? Parts that tiny can run at millions of operations a second. A Babbage machine can do a lot in a single clock cycle.
+Cooking With Cows I'm totally amazed too. I was hoping he would go into the other method of getting all the colours. Same principlal with the mirrors but there are 3 light sources pointing from different angles. So the mirrors have to move in more directions, even more tiny moving parts.
If you ever come across a 3 channel projector, they have a really neat prism inside for splitting and recombining combining the light.
I recenty bought an old 3 chip DLP projector off of ebay just so I could take it apart.
Fascinating stuff inside this thing. Might make a video!
I work on cinema projectors for a living. Those 3 DMD chip light engines are super fascinating and make up the majority of modern day cinema projectors. Single DMD chips are cool to with the color wheel they instead of the prisms.
Just so you know i was lurking through internet at 3:00 am in the morning, found this video and decided to watch it instead of sleeping ! nice video and keep them coming !
This is a necessary video because other videos tend to emphasize CGI and theory. However, this is one of those technological subjects where the old fashioned approach works best. Great video and thanks for your hard work.
You nailed it nicely!
Thumbs up from a projector sales guy of 15 years ago!
This was the best video on DLP projector technology I've seen. I love your channel. You could have made a simple color wheel to explain the secret sauce: the timing between the DMD and the wheel, but even without that, this video was excellent. Thanks!
I'd just like to say that I have been watching your videos for about a year or so now and they are amazing little lessons into your line of work and expertise. I believe the quality of the "lessons" have improved greatly and I am eager to see how this evolves in the future.
Thanks! I really appreciate your comment. Practice certainly makes it easier for me to make better videos. I've deliberated whether adding higher production value items (intro/outro, clickable links, animations, voice-overs, better shot setup, etc) would be worthwhile. I think that many folks watch my content because the videos are clear, but do not have any high production value features. They are also free of BS, rambling, paid placement, etc. On the other hand, I do wish that I could show certain concepts with animations that are more illustrative than my drawings. Let me know what your thoughts are.
Applied Science
I am part of the audience that appreciates the clarity, lack of paid placement and lack of rambling (although I think rambling can build a type of ethos similar to Q&A at the cost of clarity). I would not trade any of these "virtues" for animations (your paper ones are pretty good). I think links improve the quality of the lesson and increase chances of people watching other videos of yours and give us an idea of the sources you use. I think you already have great shot setup, voice-over and outro. I think the fact that you respond to a high number of comments is also very admirable and enhances your educational value. This channel is a great example for TH-cam education. I too am interested in the future of education and will certainly look to your channel when I finish my current schooling (PhD microbiology... I love the SEM pictures you take. I'm currently using one for my research and it is how I found your channel in the first place :D) as an example of how I might set up my own TH-cam content. Thanks again!
just replaced the DLP chip in my Mitsubishi. Super interesting to see in 'innards'. Off to see how they manufacture it now. Amazing to be able to work in such small detail.
As a kid we got a tour of a movie theater. They said that there are thousands of mirrors. I thought that they meant they were layered on top of each other. This is cool to see it under microscope, it makes way more since now.
Whoa, this was way more amazing than I thought. Thank you so much for detailed and well presented video. Seeing the actual physical item is so much amazing than an animation.
I just cannot imagine how much work has been put into the manufacturing process of this. The engineers that started this idea must've been extremely ambiguous to make this concept a reality. I can hardly even believe it.
As ever Ben, you offer a clear and accessible study of things. Many thanks for sharing your passion for investigating and questioning how things work!
for some reason this is even more amazing to me than a microprocessor, how do you make a mirror that small, how do you make that something mechanical this small operate reliably, probably millions of DLP projectors that have been running for 20 years now still out there still working.
What's also amazing is the computing and switching power to control, organize and synchronize all this stuff to make it work.
I owned a DLP rear projection TV that I kept 9 years and it never lost any pixels. The little mirrors really do last.
Interesting video, Ben. It would be cool to see your macro-DLP in action. It'd also be cool to see the area in the projector that the mirrors reflect light to when not sending it to the lens - a negative I guess.
I like the idea of taking the "negative" image and displaying it on a screen.
Interesting?! That was mind blowing! I've always wondered how those work.
Same here.
The first HDTV I ever owned was a Samsung DLP set... It was one of the earliest DLP TV sets, and it suffered from major design-flaws in the "light-tunnel" and the color wheel. The "light-tunnel" was, quite literally, a tunnel lined with mirrors that was supposed to channel light straight into the DLP chip. Stupidly, they designed it such that every *other* mirror in the tunnel was held in place with glue, and the ones that weren't held in place with glue were held in place by friction from their neighboring mirrors. So, eventually, the mirrors dropped off the sides of the "light-tunnel" and reduced the amount of light reaching the DLP chip.
The color-wheel was the 2nd problem -- it used a stepper-motor to "align" the colors with the DLP chip, which was completely ridiculous -- all it took to screw that up was one little glitch in the stepper-motor, and suddenly the colors weren't aligned properly with the picture that the DLP chip was displaying, so everything looked like a rainbow. After 3 years or so, the set was so badly compromised, that I had to toss it out and buy a new TV. Really ticked me off, too, because when it was brand-new it had a picture that was far better than any LCD or Plasma set of its day. I wish they had designed that set better.
Wow!! I took apart one of DLP-s and I found this chip, and I didn't know how this thing works without polarisation. I thought that is a normal LCD chip with mirror behind. Thank you very much for this insight! I can't believe that this projector is actually mechanical! Good work Ben, I'm looking forward to more awesome videos! Take care! :)
Thanks for showing the DLP chip under the SEM. Now I know why early DLPs were prone to pixel failures.
Cool, thanks.
I knew most of the theory, but what your videos add is always the hands-on part, actually seeing the real stuff. The missing link between theory and practice.
I always wondered what kind of "pixel" projectors used! But when I see the electron microscope image, now I wonder how on earth that can be manufactured. such tiny machinery...
I love this . DLP is working like an early color tv that used a black & white CRT and a drum that would spin a set of red green and blue film filters in front of the picture tube to create a color image. The picture tube was qued by a sensor so that the corect brightness level would be presented on the CRT to correspond to the colored film in front of it . This design was abandoned due to the larg drum spinning at 60 revolutions per second being a serious hazard if it were to break while in operation. You could still build a demo model from an old b&w tv .That would be cool to see.
Applied Science So Cool
My electromagnetics professor worked for TI and did RnD for the DMD. He gave two lectures explaining the math behind the forces of the torsion spring and the 'capacitor' (gap between mirror-plate and electrode).
The steady state relationship between the force of the torsion spring and the force between the two plates of the capacitor relative to the change in distance between the plates of the capacitor with only one intersection where the forces are equivalent, yields an astounding simplification where all variables (voltage, area of plates, spring constant) except one cancel out, leaving only the distance between the capacitor, d/3.
The d/3 represents the steady position held when the mirror is 'turned on'. When the force of the spring is equivalent to the force of the mirrors electrostatic attraction to the electrode. Which can then be calculated into the angle at which light is reflected from the mirror ... and thereby all of the mirrors in the array.
Another elegant simplification for a boundary of the laws of physics, all because we want to watch cool movies on bigger screens.
physicstasks.eu/3250/capacitor-with-plate-on-a-spring#:~:text=Air%20capacitor%20consists%20of%20two,down%20(the%20plates%20remain%20parallel.
Nice to see one under an SEM. I owned a few DLPs over the years but sadly TI seem to have stopped developing the chips any further.
Thank you for the extremely well thought out presentation concerning the T.I. DSL properties and complete explanation of that proprietary system. I have a pico-projector that implements the DSL and I have always wondered why I would catch a glimpse of the RGB in their singular state when walking by the projector or moving my head/eyes just right. That is one hell of a system and can only imagine how smart the individual is that was able to put it all together and have it work so well.....thanks again!
Its one of the best channels on YT Man !
Tons of knowledge for free and a good quality one - in depth and interesting.
One of the rare internet treasures - I think I will back it up form my children.
how are the tiny mirrors made and places where they need to be? Is it a chemical process like etching away the parts you don't need?
Good question. Yes, the chip is made by a photolithographic process, just like silicon integrated circuits. The mirror itself is made by depositing a relatively thick layer of aluminum, then etching away all of the metal between mirrors. The process will also likely require a dissolvable support material that holds the aluminum layer at the correct height, then is washed away to allow the mirror to pivot freely. I'm not sure if the DMD chip is evacuated or has an inert gas charge -- probably vacuum.
I'd like to add that often a process called MEMS "machining" (Microelectromechanical Systems) is employed nowadays in which layers are added and removed using various processes such as lithography, electron beam etching, and vapor deposition (among many many other). MEMS technology is extremely useful for manufacturing micro scale mechanical systems including gears, springs, etc. If you do a google search for "MEMS gear" there's a cool image of a spider mite sitting on top of a rack and opinion made through MEMS processes. This is also the same technology used to make digital accelerometers and gyroscopes used in everything from cell phones to F22 raptors.
gizmoguyar
www.google.com/search?tbm=isch&q=%22MEMS+gear%22
I think they etch silicon the same way they do microchips, gyro's, and accelerometers.
gizmoguyar (I did a google image search.... ) AMAZING! Awesome tiny mechanics and machines! Thanks for the info.
Superb and excellent way to make people like me understand about the mechanisms behind DLP projection.
Hats off to you for the hard work done by u to build this working mirror mechanism it’s amazing …
Thanks for sharing this complex knowledge behind DLP Chip …👏
Nice video.
Every time I think about DLP and moving mirrors I think about the sound they make. But well, they move so fast, and they are only 10um in size that I do not think they make any real sound...
I think having macro-DLP working would be cool. Even monochromatic one!
A lot of LCD projectors use a spinning color wheel with RGB filters and a monochrome LCD to generate alternating RGB sub-frames in sync with the color wheel presenting the appropriate color filter in the path of the light.
a few instrument makers have also used DMDs to provide a variable geometry input to a spectrograph, so spectra from various parts of the focal plane of a telescope can be taken simply by switching those DMD mirrors to send the light to the spectrograph input.
This is so much better than those animated videos trying to explain the same thing, thanks a lot!
Very clear and concise explanation of DLP technology.
That is so much more complicated than I had expected
It's really interesting how these projectors combine the high-tech DMD chip with the low-tech spinning color wheel. I was browsing through old Popular Mechanics magazines and the 1950 January issue was describing a color wheel TV attachment proposed by CBS as a possible way to upgrade a black-and-white set into a color set. The idea was the same as the one behind the DLP projector - have the color wheel in front of a black-and-white CRT and show red, green and blue frames fast enough for them to blend into a color image.
Very well explained i have just purchased a DLP HD projector and am amazed that one bulb can create such an amazing picture and wanted to know how and now I do thanks grate video.
finish this and play tetris on the wall.
I study Micro & Nano Systems Engineering, and this video was really helpful as an example. Thanks for the effort! It was amazing.
Ben, your channel is sweet. It's like a modern, more technical version of an old favorite of mine The Secret Life of Machines.
Very cool, I never thought about the binary nature of DLP's and how to get variable brightness from them, thank's for the info.
It's funny you put this out today, I just mentioned the rainbow effect you get from DLP like illumination in LED flat bed scanners in my last video but I filmed it months ago.
What a piece of art and technology! Thanks for bringing this so elegantly to our attention!!
I'm always sad when your videos end, I want more.
I have one of the very early generation of DLP flat screen projection tv's, it is a 30" standard def tv with 3 separate projectors, a red blue and green one with separate DLP chip's that lay there image ontop of eachother, before they had started using color wheel's. It was enormous and weighed nearly 200 LB's but quite fun to take apart. There are some newer LED projectors that use RGB LED array's for the light source so they do not need a color wheel and help with any noticeable color separation
Once took one of these apart and couldn't figure out how it worked.
Thanks for the explainer :)
If you make the suspension system for your macro-mirror device bistable you need only provide a current pulse to change its state, like a flip-disk display. Radial pre-wound chokes are probably an easy option for actuation.
Come to think of it, just buying a flip-disk display, and adding a mirror to each white pixel sounds like the easiest way. I wonder what interesting things we could make with a huge (1m square) mirror array. Hmmm.
The DMD itself is actually bistable, a large differential voltage is applied to set the mirror state then both left and right electrodes are biased to a constant voltage, so the mirror stays near the electrode it's closest to due to the stronger attraction.
LOVE your videos! I work at the US Patent & Trademark Office in Circuits and it's cool to see everything in person!
WOWWW, the effort you put in to explain this to us, thank you so much
fantastically throughout and well explained; loved the visual aids and macro model!
How does it create black? :)
***** Basically the mirrors are pulled so that they reflect the light away from the lens so that it stays within the projector instead of going onto the screen. Also, nice seeing you around here! I have watched many of your videos!
@@possiblydavid it's been five years, but five years too long that you didn't catch that this was obviously, blatantly sarcastic.
Human engineering never ceases to amaze me.
Oh, he got a real SEM now. Amazing to see those small mirrors.
Thanks for sharing. The explantion is excellent as allways.
Thank you for a great introduction to this technology. Very inspiring.
Thank you for your explanation, how fascinating this technology is!
it was very interesting and informative and i thought that was all.. then you pulled out the electron microscope...
Awesome video, very cool. I'm surprised you don't have more subscribers. Your videos are some of the most interesting and informative videos on TH-cam.
You said the hinge is made of Silicon, but it is actually made of a metal. I've more commonly heard it made of TiAl (Titanium Aluminide). Cool video :) Would have been very excited to see the Macro scale DLP project! Now i want to build something like it!
Thanks for indicating the correct material of the hinge.
Cid Vilas but also hinges and flexures are made from nickel
Very informative, even 5years later. Thank you.
that was pretty cool. very interesting. I had no idea the "mirrors" were that small. that's crazy.
A couple points:
Principal advantage to DLP is that the wasted light is wasted to a separate heat sink, NOT near the electronic device. Also, there are ways to avoid the need for the polarizing film, at least prior to the LCD, and reduce the light loss, using the mirrors or prisms to do the job via reflection, and using the pass through light at the next stage. But, it is pretty much not possible to avoid wasting at least half the light aside from modulation. Many projectors waste much more, in the interest of reducing the cost of the optics.
Great video, you forgot to mention that because the losses are much lower, DLP projectors don't heat up as much as LCD ones and are therefore potentially quieter.
8 years later. I owned a brand new 3LCD with laser technology. Very low consumption, high brightness and super silent.
This is a very useful intro to DMD / DLP, many thanks!
Very ingenious demonstration model.
really liked your video buddy no skipping or anything :) watched the whole thing
ONE OF THE BEST VIDEOS ABOUT ( DLP) SEE
Great video Ben. I see the SEM is working nicely.
Btw, Mike from mikeselectricstuff is them man. You two are star content producers. Very underrated.
Really enjoyed watching every second of this! It’s amazing what these DLP chips do. That Dell projector was my first DLP! It’s fascinating the similarities to camera sensors and I wonder why they don’t use tiny color filters over slightly smaller mirrors to actually make individual RGB pixels instead of using a color wheel. Our current projector does 3D and it’s interesting how that work as these tiny mirrors are in sync with the shutter glasses. Sometimes I do see the rainbow effect from the color wheel but it doesn’t bother me much. 😄
Old post but wanted to let you know my 2004 Samsung dlp hlp5063w is 14 years old and my Philips square lamp has 14000 hours on it which I'm going to replace soon due to dimming. I replaced the ball bearing color wheel with an air bearing and lubed the fans in 2010. I modified a small square exhaust fan and placed it on the back vent. Picture still looks awesome with my Dish satellite receiver. My next TV is gonna be an LG OLED.
Nice video ! Impressive technology :o
Laser projectors are the future. Image is always sharp, can be focused onto any surface. I believe you should make a video talking about one :)
+funky3ddy
Yes, a laser projector can produce high brightness and high contrast but there is one problem that is hard to get around and that is safety. As long as the laser beam is moving it's not a problem but what about when the software crashes and the laser spot stops moving? Someone will eventually look directly into the lens of the projector and fry their retina. No company will risk million dollar lawsuits from people with permanent black spots in their vision.
Very good explanation of DLP. Always did wonder, nut never looked it up.
Great videos. Keep up the good work.
Excellent illustration!
I just recently learned that at least one company is using DLPs to do inexpensive photolithography... that sounds to me like the sort of project you might like to take a stab at, eh? I'd love to see that! I was looking into methods by which a person might do some DIY microprocessor construction aside from FPGA.
You can have the same 3x DMD projector as the 3x LCD one (more expensive).
You can also use the same color wheel method if you want with single LCD.
There is also a LCoS that is an LCD with a mirror at the back usually also used as a single device in inexpensive projectors.
Color LED's have mostly replaced the color wheel wince you can switch fast each color LED and you do not need the color wheel that was way less efficient.
You actually need the same amount of light from the light source in a single DMD (DLP) and a 3X LCD since the mirror is mostly away from the light source so the average light output from the projector is lower.
Say you want to display RED with DLP (you will need to wait for the RED part of the color wheel usually a quarter of is size so just a quarter of the time the mirror will reflect the light outside the projector and that is only for the part of the light source since just the red part of the spectrum will go trough).
On a 3LCD projector the RED part of the spectrum will go trough one of the 3x LCD's but for the full period not just 1/4.
Some years ago I used to play with old projectors and replace the original lamp with white LED's (that was before LED projector got popular).
I got about 25lumen to 30lumen from a single 6W white LED with 3x LCD projectors. I prefer 3xLCD the most since each pixel has his color there are no color sub-pixels as on monitors so you can have a yellow pixel. And also there is no flicker or that rainbow effect you get with a single DMD or single LCoS.
Excellent, makes this very easy to understand - thank you.
Definitely an interesting video as I begin to research and muck about with DLP 3D printing.
I love this micro suspension! Great episode as always!
The damage done by the tweezers makes it obvious why it was originally in that protective case. It would make cleaning the assembly many times easier too since all the fragile parts are inside and all you would have to do is wipe the glass.
By the way, this is my favorite channel.
I hope you will show us your macro scale DLP when it is finished !
Hi Ben you explain in a wonderful way....
I just wonder how do they create, and fix such tiny mirrors and the hinges mechanism in the DLP production factory !!!
The lens that makes it so the light doesn't spread out (uniform irradiance) isn't a biconvex lens like you've drawn, it's a fly's eye lens, which is a microlens array that captures light from many different perspectives and focuses it on a fixed area
Wow! Such a great explanation once again, Ben! Thanks.
Great video! As the video explains DMD's working, I suggest you tag 'MEMS' in the video's name and description.
Coolest thing I've seen in a while. I had no clue how it worked. Thanks
I learnt loads from this. Great presentation , thanks!
DLP is fine for projecting things like PowerPoint slides and other static images. The problem is with action subjects. When "Band of Brothers" was released on DVD, my friends and I watched a couple episodes each week and used a DLP projector on a portable DaLite movie screen. The high contrast, fast action sequences of World War II in the video caused such color separation that I could barely stand to watch it. Some of the guys saw it, others didn't.
I am so glad I found your channel. Great stuff!!!
I would have thought this idea to be ridiculous. I am impressed by those who made it work.
Reminds me of a Mohammed Ali quote : "Impossible is not a fact. It is an opinion."
You would make a very good teacher.
i never seen exploration like this thank you sir
Great tutorial !!. Congrats !! I needed to understand DLP technology in an easy way. This video worked for me!. Thanks a lot !!
great video with outstanding explanation
I'd love to see The Slow Mo Guys check out those transitions between colors 🤩!
I love learning about this stuff. Makes everyday life more exciting knowing what kind of amazing tech is around you. Does anyone have any sources explaining how this is manufactured? Or anything on this scale, really? I've never learned how such microscopic products are massively produced.
You explained that in a very easy to understand manner, the model you made is probably how they came across the dmd development.
I got a led DLP projector, would that have a colour wheel or a RGB LED that does the colour work? I'm guessing the latter but don't want to dismantle it.
Very nice and clear video. Thanks for uploading.
Wow! Well done! Thanks for the video. Very clever science taking place.