The inception of digital cinema and the journey ahead

May 16, 1999 marked the transition from film to digital cinema with the premiere of "Star Wars: Episode 1 – The Phantom Menace," the first movie shown publicly on a digital projector using DLP Cinema® technology.

DLP technology uses digital micromirror devices (DMDs), an array of millions of micromirrors with an illumination source to project an output.

How did DLP cinema technology go from a low-resolution prototype to changing not only how we experience movies, but the way we interact with countless applications?

DLP® technology in cinema

Before the inception of digital display, movie makers used celluloid film. Film was fragile and expensive to replicate, making it hard to transport to movie theaters without damage. “Movies were limited to a couple of thousand theaters that could premiere it the opening day,” said Dave Duncan, former DLP® front projection and DLP Cinema business manager at our company.

Even if a film arrived in pristine condition in cities like New York or Los Angeles, in smaller towns and theaters, its condition was nowhere near the original. Film’s delicate nature meant that repeated usage and transportation caused blemishes and imperfections. “By the time we saw a film in in my hometown of West Lafayette, Indiana, it was scratched and faded,” Dave said.

In the 1990s, Dave and his team traveled to Hollywood to perfect the prototype using expertise from the film industry. They met with producers, directors, cinematographers and distribution executives, as well as technologists responsible for cinematic advancements. For months, the DLP products team integrated their feedback to perfect the technology. When the technologists could no longer differentiate between film and a digital image, the team knew that “they had changed cinema forever,” Dave said, and enabled a consistent experience for moviegoing audiences.

Movies and more

Even though the cinema industry has changed dramatically in the past 25 years, the ways in which DLP technology changes how people experience and access the technology has not.

“When you view a DLP technology-based display, it grabs your attention because of its bright colors, high contrast and crisp image. Historically, DLP technology has always been about a magical and immersive experience,” said Jeff Marsh, vice president and general manager of DLP products for our company. Across several industries and spaces, including automotive, education and gaming, DLP technology helps emphasize the visual experience for the user.

In the automotive sector, DLP technology helps make the driving experience safer, with enhanced vehicle-to-pedestrian and vehicle-to-vehicle communication. Light-steering headlights help drivers detect pedestrians and adapt to the conditions, turning headlights off or brightening and dimming them.

In the classroom, technologies such as interactive whiteboards only allow one or two students to interact with the content. DLP projectors can make the entire wall an interactive display, creating a more engaging and inclusive experience for larger groups of students and teachers.

DLP technology is even changing the way we interact with video games. New display products now enable lower latency than ever before, resulting in projectors that can compete with the fastest gaming monitors.

"We produce amazing display products that people view. But we also offer light control products where it's not about display at all," Jeff said, referring to DLP technology in applications such as printed circuit board (PCB) manufacturing or industrial 3D printing. For example, in PCB manufacturing, DLP light control technology is driving the transition from masked lithography to direct laser imaging. Whenever masks are used and design changes are required, they must be completely replaced. These masks also deteriorate and incur other costs such as cleaning and inspection. With DLP technology's real-time programmability and resolution, direct laser imaging reduces total manufacturing costs and improves yields of produced usable units. This technique also allows for narrower line spacing between traces, or conductive paths which carry electrical current, for advanced packaging opportunities, ultimately placing semiconductor chips closer together.

For industrial 3D printing, DLP technology can project a variety of light wavelengths to fuse or harden mediums for highly accurate exposure, fast update speed and reliable operation. Using DLP products for manufacturing can promote faster design cycles, help adjust prototypes faster, and ultimately print production parts.

Looking ahead

Today, nine out of 10 theaters use DLP technology for its image quality. In the same spirit of their accomplishments in digital projection and cinema, the DLP team is constantly looking for ways to improve and innovate. DLP technology now is smaller and more affordable than ever.

“Augmented reality glasses, gaming monitors and interior projection displays in automobiles would not have been on our radar 10 years ago. As we’ve advanced the technology, we’ve opened up new doors,” Jeff said.

As the DLP team celebrates its rich history and influence in cinema, they also look toward the future. “Projection display is our cornerstone,” Jeff said. “Because of it, we can expand to new applications. And we are just getting started.”