Topology Optimization, Part Orientation, and Symmetry Operations as Elements of a Framework for Design and Production Planning Process in Additive Manufacturing L-PBF Technology

Abstract

This paper investigates the possibility of the application of different optimization techniques in the design and production planning phase in the metal additive manufacturing process, specifically laser powder bed fusion (L-PBF) additive technology. This technology has a significant market share and belongs to the group of mature additive technology for the production of end-use metal parts. In the application of this technology, there is a space for additional cost/time reduction by simultaneously optimizing topology structure and part orientations. Simultaneous optimization reduces the production time and, indirectly, the cost of parts production, which is the goal of effective process planning. The novelty in this paper is the comparison of the part orientation solutions defined by the software algorithm and the experienced operator, where the optimal result was selected from the aspect of time and production costs. A feature recognition method together with symmetry operations in the part orientation process were also examined. A framework for the optimal additive manufacturing planning process has been proposed. This framework consists of design and production planning phases, within which there are several other activities: the redesign of the part, topological optimization, the creation of alternative build orientations (ABOs), and, as a final step, the selection of the optimal build orientation (OBO) using the multi-criteria decision method (MCDM). The results obtained after the MCDM hybrid method application clearly indicated that simultaneous topology optimization and part orientation has significant influence on the cost and time of the additive manufacturing process. The paper also proposed a further research direction that should take into consideration the mechanical as well as geometric, dimensioning and tolerances (GDT) characteristics of the part during the process of ABOs and OBO, as well as the uses of symmetry in these fields.