Efficient parts nesting schemes for improving stereolithography utilization

In the present paper, the platform layout optimization problem for the simultaneous fabrication of different parts, which is addressed in the batch planning of Stereolithography Additive Manufacturing technology, is studied. The methodology proposed in the paper employs a Genetic Algorithm technique for the 2D nesting of parts on the platform of the stereolithography machine. The build orientation of the parts is assumed fixed and is decided prior to layout optimization, according to part-specific quality and cost requirements. Three placement schemes, appropriately adapted to the problem, are considered for the parts nesting and fabrication layout definition. The algorithms and placement schemes developed are evaluated in several test cases/benchmarks involving parts with both simple and complex geometries. The computational results included in the paper indicate that the proposed methodology can lead to satisfactory layout/packing–nesting arrangements in a time efficient manner, leading, therefore, to substantial improvement of stereolithography machine utilization.

► The parts packing problem in stereolithography job planning is investigated. ► Due to the requirement for supports the problem is reduced to two dimensions. ► Three appropriately adapted 2D nesting schemes are developed and evaluated. ► The genetic algorithm technique is employed for nesting optimization. ► The combined rule-based/no-fit polygon scheme is the most efficient.