A large variation in part size across the projection area of the microscale selective laser sintering process
is caused by non-uniform intensity projected onto the substrate by the digital micromirror device (DMD).
A corrective gray scale mask with varying intensities was mapped according to a sintered array of parts.
The variance in part size across the area was reduced by as much as 45% by using this technique. This
approach can be extended to in real-time process control to create a more uniform distribution of heat
and in turn better near net shape parts across the projection area.