Automated Geometric Correction System for Additive Manufacturing Considering Build Orientation

One of the current challenges for the additive manufacturing (AM) industry lies in providing component designs compatible with the AM manufacturability and constraints without compromising the component structural functionalities. To address this challenge, we present an automated correction system that provides geometrically feasible designs for additive processes by applying locally effective modifications while avoiding substantial changes in the current designs. Considering a minimum printable feature size from the process parameters, this system identifies the problematic features in an infeasible part’s design using a holistic geometric assessment algorithm. Based on the obtained manufacturability feedback, the system then corrects the detected problematic regions using a set of appropriate redesign solutions through an automated procedure. In addition, to reduce the difference between the current and modified part geometries, a novel optimization model for build orientation is presented. By using this model, one can identify appropriate orientations for obtaining a feasible design with a minimal amount of corrections while also reducing the postprocessing effort by minimizing the area of contact with the support structure. The functionalities of the presented correction system and the optimization model are illustrated using a number of case studies with varying geometries. The computational performance of the system and an experimental validation are also presented to demonstrate the effectiveness of the implemented detection and modification approaches.