Digital fringe projection (DFP) enables micrometer-level 3D reconstruction, yet extending it to large-scale mapping remains challenging because six-degree-of-freedom pose estimation often cannot match the reconstruction’s precision. Conventional iterative closest point (ICP) registration becomes inefficient on multi-million-point clouds and typically relies on downsampling or feature-based selection, which can reduce local detail and degrade pose precision. Drift-correction methods improve long-term consistency but do not resolve sampling sensitivity in dense DFP point clouds. We propose a high-precision pose estimation method that augments a moving DFP system with a fixed, intrinsically calibrated global projector. Using the global projector’s phase-derived pixel constraints and a PnP-style reprojection objective, the method estimates the DFP system pose in a fixed reference frame without relying on deterministic feature extraction, and we experimentally demonstrate sampling invariance under coordinate-preserving subsampling. Experiments demonstrate sub-millimeter pose accuracy against a reference with quantified uncertainty bounds, high repeatability under aggressive subsampling, robust operation on homogeneous surfaces and low-overlap views, and reduced error accumulation when used to correct ICP-based trajectories. The method extends DFP toward accurate 3D mapping in quasi-static scenarios such as inspection and metrology, with the trade-off of time-multiplexed acquisition for the additional projector measurements.

We propose a novel omnidirectional structured light system comprising a fisheye camera and a catadioptric projector, enabling dense 3D reconstruction. In addition, we present a streamlined calibration procedure that calibrates the entire procedure using only a planar checkerboard and demonstrates robust convergence and a high success rate even under unfavorable parameter initialization. Experimental results validate the proposed method, achieving reprojection errors of 0.43 pixels for the camera and 0.63 pixels for the projector. Furthermore, the practical utility of the system is confirmed through successful dense 3D reconstructions. The source code is available at: https://github.com/GotoIlsan/Omnidirectional-Structured-Light-System.