Minimizing form errors in additive manufacturing with part build orientation: An optimization method for continuous solution spaces

Abstract

For additive manufacturing (AM) to be successfully implemented in manufacturing systems, the geometric accuracy of components must be controlled in terms of form, fit, and function. Because the accuracy of AM products is greatly affected by the part build orientation, this factor dictates the achievable tolerances and thereby the ability to incorporate AM technologies in a large-scale production. This article describes a novel optimization method for minimizing form errors based on the geometric features of the part. The described method enables the combination of separate expressions for each feature to create a continuous solution space. Consequently, the optimal part build orientation can be precisely determined based on a mathematical description of the effect of build direction on each surface type. The proposed method is demonstrated in two case studies by step-by-step descriptions including discussions on viability and possible extensions. The results indicate good performance and enable flexible prioritization and trade-offs between tolerance characteristics.