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Multi-orientation optimization of complex parts based on model segmentation in additive manufacturing

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Abstract

Build orientation has a significant impact on the surface quality, support structure, and final cost of the fabricated model. In this study, we focus our attention on the surface quality and printing cost of complex parts when fabricated under multiple build orientations. A novel method using model segmentation is proposed to search for an optimal build orientation for each sub-model decomposed by Reeb graph. The sub-model is divided into separate regions that are treated differently based on modified curvature shift strategy. Every flat facet of the regions is given a different weight factor to build the volume error function. The optimal build orientation for each sub-model is the one leading to the minimal error of the volume error function. The case study demonstrates that the proposed method obtains a smaller error without any support structure. The model surface in higher weighted regions obtains a higher surface quality and is more cost saving when printed, especially for complex models.

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Abbreviations

AM :

Addictive manufacturing

S :

The hash matrix

c max :

The maximum curvature

Cs v :

Curvature shift vector

V i :

The shift vector

p i :

The ith point

c p :

The curvature of pi

c m :

The mean curvature

k x :

The kernel function

c av :

The average curvature

c f :

The curvature of one face

w c :

The cluster weight

w(c) :

The curvature weight

w(d) :

The gaussian distance weight

w cl :

The local weight

w f :

The facet weight

ΔV :

The volume error of one face

V :

The whole volume error of the model

c cusp :

The cusp height

θ i :

The angle between facet normal and Z-axis

\({\vec n}\) :

The facet normal

\({\vec d}\) :

The build orientation

L P :

The projection length of all facet normals

K i :

The projection length of the normal vector

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Acknowledgments

This research was funded by National Natural Science Foundation of China (No. 51935009; 51821093), Zhejiang Key Research and Development Project (LGG20E050006; LGG21 E050020), Zhejiang University president special fund financed by Zhejiang province (2021XZZX008).

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Authors and Affiliations

  1. School of Mechanical Engineering, Zhejiang University, 38 Zheda Road, Hangzhou, 310027, Zhejiang Province, China

    Hongshuai Guo, Jinghua Xu, Shuyou Zhang, Yiming Zhang & Jianrong Tan

  2. State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, 38 Zheda Road, Hangzhou, 310027, Zhejiang Province, China

    Jinghua Xu, Shuyou Zhang, Yiming Zhang & Jianrong Tan

  3. Key Lab of Advanced Manufacturing Technology of Zhejiang Province, 38 Zheda Road, Hangzhou, 310027, Zhejiang Province, China

    Jinghua Xu, Shuyou Zhang, Yiming Zhang & Jianrong Tan

Authors
  1. Hongshuai Guo
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  2. Jinghua Xu
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  3. Shuyou Zhang
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  4. Yiming Zhang
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Corresponding author

Correspondence to Jinghua Xu.

Additional information

Hongshuai Guo is currently a Ph.D. student in the School of Mechanical Engineering, Zhejiang University, Hangzhou, Zhejiang Province, China. His research interests include computational geometry, computer graphics, 3D printing, topology analysis, etc.

Jianghua Xu is currently an Associate Professor in the School of Mechanical Engineering, Zhejiang University, Hangzhou, Zhejiang Province, China. His research interests include computer graphics, 3D printing, machine computer vision, digital prototyping, etc.

Shuyou Zhang is currently a Professor in the School of Mechanical Engineering, Zhejiang University, Hangzhou, Zhejiang Province, China. His research interests include product digital design, intelligent design and simulation analysis of complex equipment, computer graphics, etc.

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Guo, H., Xu, J., Zhang, S. et al. Multi-orientation optimization of complex parts based on model segmentation in additive manufacturing. J Mech Sci Technol 37, 317–331 (2023). https://doi.org/10.1007/s12206-022-1231-2

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  • DOI: https://doi.org/10.1007/s12206-022-1231-2

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