Determination of optimal build direction in rapid prototyping with variable slicing

Abstract

Several important factors must be taken into consideration in order to maximize the efficiency of rapid prototyping (RP) processes. The ability to select the optimal orientation of the build direction is one of the most critical factors in using RP processes, since it affects part quality, build time, and part cost. This study aims to determine the optimal build-up direction when a part is built with the variable layer thickness for different RP systems. The average weighted surface roughness (AWSR) that is generated from the stair stepping effect, the build time, and the part cost using the variable layer thickness are all considered in the process. Using the multi-attribute decision-making method, the best orientation is determined among the orientation candidates chosen from the convex hull of a model. The validity of the algorithm is illustrated by an example. The algorithm can help RP users select the best build-up direction of the part and create an efficient process planning.

Design for Wire + Arc Additive Manufacture: design rules and build orientation selection

“…Build orientation selection is a key aspect of AM build strategy and is a trade-off between build time, surface finish and manufacturing cost. Several researchers have proposed methods to optimise the build orientation of rapid prototyped parts (Byun and Lee 2006;Canellidis, Giannatsis, and Dedoussis 2009;Kulkarni, Marsan, and Dutta 2000). Kulkarni, Marsan, and Dutta (2000) state that build orientation and support structure generation are key tasks to be performed in the model domain of process planning for layered manufacturing of polymer parts.…”

A novel methodology of design for Additive Manufacturing applied to Additive Laser Manufacturing process

“…The orientation problem is, in the case of the Additive Manufacturing processes, a multi-criteria problem since both the fabrication cost and quality for a given orientation needs to be assessed. In order to take into account the both, decision support tools have been developed in recent years, they provide estimations of surface roughness, accuracy, time, and cost in order to help the operator in the estimation of the quality-cost trade-offs in orientation selection [16,17]. These numerical tools have been developed to help the manufacturing operator in the pre-processing phase and are exclusively applied to the CAD model of the parts.…”

Efficient slicing procedure based on adaptive layer depth normal image

“…In the proposed adaptive LDNI slicing algorithm, the input model is assumed to be a homogeneous object while discussion of slicing technique for heterogeneous objects can be found in [26]. The slicing direction in the proposed prototype system can be set manually to axis-aligned direction or automatically after Byun et al [27].…”