Geometric Analysis for Concurrent Process Optimization of AM

Build orientation and deposition direction are two important AM process parameters which are determined at the pre-processing stage of AM. Carefully determined build direction and deposition direction can significantly improve the process and fabrication attributes. Either build direction or deposition direction is usually optimized independently considering one or multiple attributes. Such approach undermines the hierarchical relationship in the AM process plan and may produce sub-optimal solution. Besides, both build direction and deposition direction alter the layer topology and tool-path pattern which eventually determine the process and part attributes. But, the geometry is not taken into consideration while determining the build and deposition orientation. In this paper, an integrated framework is proposed to concurrently determine the optimum build orientation and tool-path/deposition direction using Genetic Algorithm (GA). The proposed methodology is designed on the basis of the layer geometries and the resulting part attributes to ensure manufacturability and minimize fabrication complexity for parts in AM processes. The proposed algorithm is implemented on two free form shaped objects and the process converges within a reasonable number of iterations.