A new algorithm for optimal process parameters based on minimum building time in additive manufacturing

Abstract

Abstract Background Additive manufacturing method is used for manufacturing of solid three-dimensional parts. It requires less human efforts and manufacturing time for parts is less. Different process parameters such as layer thickness, building orientation, infill type, and infill percentage affect the building time, model cost, mechanical properties, and surface roughness. The presented paper develops an algorithm for adapting layers and generating tool-paths. This algorithm can improve the fabrication efficiency and geometrical accuracy in the additive manufacturing (AM) of complex models. The proposed algorithm consists of three modules that identify the optimal process parameters, named as part building orientation, layer thickness, strategy type for internal filling, and slope of the tool-path. Results The input is the PTS file that contains the points of the layers contour of the computer-aided design (CAD) model. All the modules for the proposed algorithm were implemented using the MATLAB R2019a programming language software. The main finding results showed that the fabrication with an adaptive layer thickness was more time-efficient. The build time was reduced up to 47.3%. The developed tool-path generation strategies (contour offset and zigzag line tool-path) can effectively balance the AM surface quality and fabrication efficiency requirements. Conclusion In this research, the AM users can benefit by saving the cost and time. The parts were fabricated with a high degree of accuracy, and the surface finish was suitable for determining the optimal process parameter.

Keywords

• Additive manufacturing
• Adaptive layer thickness
• Model orientation
• Fabricating efficiency
• Geometrical accuracy
• Filling strategy