Additive Manufacturing Orientation Algorithm
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Solution Overview
Problem
Additive manufacturing processes face challenges in controlling the dimensions and surface finish of three-dimensional objects, with economic and schedule constraints affecting design, particularly in terms of material usage and time, and existing algorithms do not adequately consider factors influencing the quality of the final product.
Innovation Solution
A method and algorithm that select an optimal manufacturing orientation for three-dimensional objects by analyzing angles and surface properties to minimize stair stepping and material usage, thereby improving surface finish, mechanical properties, and reducing production time by using a reduced number of substrate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the object is oriented to minimize stair stepping and improve surface finish, then the surface quality is improved, but the manufacturing time increases due to reduced number of substrate layers
Solution Approach 1:
The algorithm performs preliminary analysis of the object model to determine optimal manufacturing orientation before production begins. By pre-calculating the best orientation based on surface angle evaluation and stair stepping minimization, the system establishes optimal parameters in advance, allowing the manufacturing process to proceed efficiently without time-consuming adjustments during execution.
Solution Approach 2:
The system changes the orientation parameter of the object model to achieve optimal manufacturing conditions. By rotating or repositioning the object in the manufacturing space, the algorithm modifies critical parameters (surface angles relative to build planes) to minimize stair stepping effects and optimize layer deposition, thereby improving surface finish while controlling manufacturing time.
2Loss of substance
If the object is oriented to reduce material usage, then material costs are reduced, but the manufacturing time increases
Solution Approach 1:
The algorithm modifies orientation parameters to optimize material utilization. By changing the object's orientation relative to the build platform, the system minimizes the number of substrate layers required and reduces material waste from support structures and failed prints, achieving material efficiency without proportionally increasing manufacturing time.
Solution Approach 2:
The system performs preliminary orientation optimization to determine the most material-efficient configuration before manufacturing begins. By pre-calculating the optimal orientation based on object geometry and manufacturing constraints, the system establishes a plan that minimizes material usage from the start, avoiding the need for time-consuming material adjustments during the manufacturing process.
3Strength
If the object is oriented to improve mechanical properties, then the strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The algorithm optimizes orientation parameters to enhance mechanical properties such as strength and structural integrity. By carefully selecting the object's orientation relative to the build platform, the system ensures that load-bearing surfaces are positioned to maximize structural strength while maintaining manufacturing simplicity and avoiding excessive complexity in the manufacturing process.
Data Source
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AI summary
A non-transitory machine-readable storage medium storing instructions executable a processor is described. In some examples, the instructions cause the processor to receive object data representing an object to be manufactured by an additive manufacturing process. The object data comprises data representing a plurality of planar surfaces of the object. The object data is processed to determine, for each of the plurality of planar surfaces, an angle between the respective planar surface and a plane of a reference surface of an additive manufacturing apparatus. A manufacturing orientation of the object is selected on the basis of the angles determined for the plurality of planar surfaces and a further property of the object different to the determined angles.