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

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.