System and method for transforming graphical images

A method for transforming a two-dimensional graphic image into a two-dimensional distorted graphical image which is to be pre-applied onto a three-dimensional surface of a formed part, the method comprising the steps of:

• providing a plurality of flat webs each having a grid pattern printed thereon, the grid pattern comprising a uniform array of grid markers (grid dots) separated from each other by a space, the webs each being formed of a thermally transformable material;
• thermally transforming each of the polymer webs into the three-dimension surface;
• selecting a representative sample of the grid markers common to each polymer web;
• measuring and recording positions for each grid marker in the representative sample of grid markers for each thermally transformed web;
• selecting a single target grid from the plurality of transformed polymer webs, the target grid being selected by choosing the transformed polymer web whose grid markers in the representative sample reside closest to a center of variance of the positions of the grid markers in the representative sample of all of the transformed webs;
• digitizing the three-dimensional shape of the target grid to form a digital representation of the target grid as a series of data points;
• creating a smooth, distinct 3D model containing a precise delineation of the series of data points, with the ability to have texture data attached to it, and able to manipulate its data to output new texture graphics and data;
• texture mapping the two-dimensional graphic bitmap image onto the distinct 3D model to create a texture map, and
• creating a two-dimensional distorted image by rendering the processed (distorted) texture map.

A method of creating a 3D target grid to be used as a physical 3D model for transforming a two-dimensional graphic image into a two-dimensional distorted graphical image which is to be pre-applied onto a three-dimensional surface of a formed part, the method comprising the steps of:

• providing a plurality of flat webs each having a grid pattern printed thereon, the grid pattern comprising a uniform array of grid markers (grid dots) separated from each other by a space, the webs each being formed of a thermally transformable material;
• forming each of the webs into the three-dimension surface;
• selecting a representative sample of the grid markers common to each flat web;
• measuring and recording positions for each grid marker in the representative sample of grid markers for each formed web, and
• a selecting a target grid from the plurality of formed webs, the target grid being selected by choosing the formed web whose grid markers in the representative sample reside closest to a center of variance of the positions of the grid markers in the representative sample of all of the formed webs.