3d Printing Part Orientation Optimization
3d Printing Part Orientation Optimization
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Article in International Journal of Electrical and Computer Engineering (IJECE) · December 2022
DOI: 10.11591/ijece.v12i6.pp5958-5966
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Juan C. Guacheta Alba, Sebastian Gonzalez Garzon, Diego A. Nunez, Mauricio Mauledoux,
Oscar F. Aviles
DAVINCI Research Group, Mechatronics Engineering Department, Universidad Militar Nueva Granada, Colombia
Corresponding Author:
Juan C. Guacheta Alba
DAVINCI Research Group, Mechatronics Engineering Department, Universidad Militar Nueva Granada
Carrera 11 # 101-80, Bogotá D. C., Colombia
Email: est.juan.guacheta@unimilitar.edu.co
1. INTRODUCTION
Additive manufacturing (AM), or more commonly known as 3D printing, consist of manufacturing
parts employing layer-by-layer material deposition, covering the solid volume. The movements made by the
printing nozzle are linked to the piece structure and orientation, and these determine the mechanical behavior
of the part and its texture and quality [1], [2]. The part's orientation is an initial parameter for its
manufacturing and is commonly set by the user. However, this variable is associated with characteristics of
the final product such as the model precision, the number of supports required, and the processing time for its
production [3], [4], as well as crucial end-user criteria, such as aesthetics, smoothness, material cost, and
energy spent in manufacturing [5]–[8]. Some issues related to wrong printing orientation are volumetric errors
that deform the part, high presence of the staircase effect represented in poor surface quality, high construction
time [4], material consumption [8], [9], anisotropy [10], and cylindricity and flatness errors [11]–[13].
3D printing has capability to manufacture any geometry compared to other manufacturing
processes. However, it is necessary for several parts to print support structures that guarantee structural
stability and avoid the collapse or deformation of the material in the regions with overhangs in the
manufacturing process [9], [14]. This support is eventually represented in waste material, additional costs
[15], and possible defects on the surfaces [9]. There are support materials that can be removed chemically,
improving the result of the part [14]. However, it is an additional process that affects the manufacturing time
and cost. This material is directly related to the support volume, which corresponds to the region used to
construct the holdup structure.
Some aspects such as: concavity, geometric shape, size, and islands must be considered to define
and obtain the support volume of the parts to be manufactured [16]. To treat and analyze the support volume,
it is crucial to consider a continuous but non-smooth function concerning the orientation angles [17]. Its
behavior will be defined by the geometry of the part to be manufactured. Several authors propose strategies
to obtain or approximate the support volume, such as the use of the kth nearest point algorithm [16], convex
hull surface triangles method [13], or a Quadtree decomposition [8] to find the volume of support structures.
Another essential aspect considered in the aforementioned strategies is the minimum self-support angle,
which is suggested for direct metal laser sintering (DMLS) printed parts of 45 degrees [14].
The above considerations have been a topic of study to optimize objective functions to improve the
printing process, being the principal applied function of the support volume. Some mono-objective
optimization techniques that have been applied to this problem are particle swarm optimization (PSO) [7],
ray-tracing method [13], optimization methods like electromagnetism [4], or perceptual models [9]. These
techniques become complex in their programming and implementation but guarantee to obtain global
solutions to the problem. Along with the support volume, multi-objective techniques have been applied to
optimize more objective functions, such as resolution error [5], [11], surface roughness [18], printing time,
and the number of aggregate suspensions [3]. The main multi-objective techniques used to solve this
optimization problem are genetic algorithms [3] and particle swarm optimizers [15].
Due to this, there is no evidence that focuses on optimizing the orientation of pieces that guarantees
a lower volume of supports. This work presents a solution using multivariate optimization techniques. This
paper is organized as follows: section 2 defines the method used to minimize the support material, employing
a correct orientation in printing pieces and multivariate optimization algorithms. Section 3 presents the
results obtained on a set of pieces. Also, the performance of the applied algorithms is compared. Finally,
section 4 points out the recommended algorithms in multivariate problems and exposes a discrete
approximation validation compared with commercial software. The following sections expose the capacity of
the discrete approximation of continuous problems and the feasibility of applying simple multivariate
optimization algorithms in problems with application in additive manufacturing, saving costs and time in
manufacturing pieces.
2. METHOD
The main objective of this work is to present an algorithm for optimizing the piece orientation. This
process requires several steps described below: first, it is required to define the decision variables that
correspond to the rotation angles of any piece in STL format. Second, the mathematical formulation and
programming of the objective function to be optimized, corresponding to the approximation of the volume
used to print the support material required in the printing. Third, the five multivariate optimization algorithms
used to solve the formulated problem are exposed as the performance metrics. At the end of this chapter, the
case study section presents pieces used to assess the algorithms and metrics.
With the three decision variables defined, the discrete approximation of the support volume is defined, which
corresponds to the objective function to be minimized. The discrete approximation of the support volume is
performed with the three defined decision variables, which corresponds to the objective function to be
minimized. When the part is obtained and the rotation matrix is applied, an octahedral mesh of thickness d is
created, completely covering the part. The mesh size affects the computing time and the precision of the
approximation of the support volume. The mesh is swept in the z-direction, and at each point it is evaluated
whether it corresponds to a region to be supported, considering the 45-degree rule for overhangs [14].
The pseudocode of this objective function is shown in Algorithm 1. Although it is possible with two
angles to find the orientations for printing, the discrete approach used to obtain the support volume is decided
to use the three angles. For selecting search methods and algorithms applied to the proposed problem, its
formal definition is made, which is an unconstrained single-objective multivariable optimization problem.
This problem is focused on its application on 3D printers and is mathematically represented in (2), where 𝑥
3D printing part orientation optimization: Discrete approximation … (Juan C. Guacheta Alba)
5960 ISSN: 2088-8708
corresponds to the angles roll (ψ), pitch (θ ) and yaw (φ ), while 𝑓(𝑥) corresponds to the approximate
support volume. Although the desired solution is sought in a range from -𝜋 to 𝜋, they are not constraints to
allow transitions between quadrants.
In Figure 1, the massive overhang test by Thingster is used to evaluate the performance of the
designed discrete objective function and its frame of reference is presented, as well as the rotation angles. It
can be observed that the volume covered with support material is not calculated for print angles less than 45
degrees. In contrast, for angles greater than this angle, this volume is approximated by the lower mesh. The
region of the mesh that approximates the support volume on the parts used in this paper is shown in green.
Int J Elec & Comp Eng, Vol. 12, No. 6, December 2022: 5958-5966
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− Approximate part support volume: this metric corresponds to the objective function described in
Algorithm 1 and is expressed in mm3. A weighted average is performed on each implemented algorithm
for its evaluation, using (3), where x represents the approximate volume obtained for each part. In
contrast, w represents the inverse of the total volume of the part mesh, which is represented as a
percentage of deposited material for the mesh used.
− Algorithm execution time: this time is captured using a stopwatch timer and was taken only from the
algorithm, without considering the part reading or variable initialization, and is expressed in seconds. A
weighted average (𝑥̅ ) is performed using (3), where 𝑥 corresponds to the estimated time and weights 𝑤
corresponds to the inverse of the part mesh size.
∑ 𝑥𝑖 𝑤𝑖
𝑥̅ = ∑ 𝑤𝑖
(3)
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such as the ‘Frog ring’ piece exposed in Figure 3(a). In addition, it also correctly solves other parts, such as
the ‘Bunny's head’, shown in Figure 3(b), which has a hollow presence in its geometry, and large curved
sections, offering the user a solution that is not easy to obtain. In addition, in Figures 3(c) and 3(d), we can
see the prevalence of the 45-degree rule for printing, where a defined orientation for a flat face in these cases
results in greater volume and support material.
Figure 3. Support volume in optimal piece orientations (a) frog ring, (b) Samsung stand, (c) measuring cup,
and (d) bunny's head.
To analyze the accuracy and speed of the algorithms, Figure 4 shows their performance curves in
the search for the orientation of the ‘Geo cube’ piece. The evolutionary operation and random walk
algorithms, on this optimization problem, have a faster convergence, also with a high accuracy on the first
iterations. Meanwhile, it is shown that the simplex algorithm finds with good accuracy the optimal solution,
but in a long time. On the other hand, the MATLAB fmincon function has low precision and the MATLAB
ga function consumes a high computation time per iteration.
Once the results related to the orientations obtained by the algorithms that most effectively
minimized the support volume have been analyzed, each algorithm's efficiency on all the pieces is analyzed.
For this, the evaluation metrics defined in section 2.4 are used: the approximate support volume of the part
and the algorithm time. It denotes that the weighted average is made using (3) on each algorithm for the set
of pieces. Table 2 shows the results of the metrics mentioned. These result from the weighted average for all
the pieces on each algorithm. The evolutionary operation search method found better solutions to the selected
parts for the approximate support volume metric, outperforming the simplex method and the MATLAB
genetic algorithm. The better result of the direct search methods is presented because the optimization
problem does not become complex and allows applying techniques based on the direct search. In addition,
being a discrete approximate function, the evolutionary operation algorithm facilitates its implementation and
execution.
On the other hand, the runtime metric for each algorithm performs better with MATLAB fmincon
function. However, these results are variant by part, as some are solved efficiently, while others do not
converge quickly. All algorithms consume a similar execution time except for the MATLAB genetic
algorithm, which takes 20 times longer due to its nature and the number of evaluations required on the
objective function. Finally, to corroborate the correct approximation of the volume to be coated required by
the support material, the open software PrusaSlicer is used, which exposes the printed material for the
manufacture of parts graphically. Figure 5 shows the approximation performed on the ‘3Dbenchy’ part in
Figure 5(a) and after, a support material by PrusaSlicer in Figure 5(b), presenting a similar result in both
cases. Because it is an approximation, the programmed objective function does not consider the necessary
support on the front holes of the part. However, it works correctly for orientation optimization, and the
discrete objective function is valid.
Table 2. Weighted results of volume and computation time metrics for all parts
Optimization techniques Volume [mm3] Time [s]
Random walk 135.5765 46.9499
Evolutionary operation 100.6915 45.1587
Simplex method 126.3512 44.5598
fmincon by MATLAB 194.9746 43.8417
GA by MATLAB 132.5944 947.53
(a) (b)
Figure 5. Support material used for ‘3Dbenchy’ printing (a) objective function and (b) PrusaSlicer
4. CONCLUSION
Direct search methods are not commonly used due to their rapid convergence into local solutions.
However, they can be applied to unrestricted problems with a finite search range and achieve good results.
Comparing the performance of the executed algorithms, it was observed that the random walk and
operational evolution methods were able to find the global minimum on the orientation optimization
problem. In contrast to this, the simplex method found local solutions, verified by the genetic algorithm used.
On the support volume optimization problem, the operational evolution method was the one that obtained the
best results, and with an execution time like that obtained by the MATLAB fmincon function. Simple search
methods were applied, which have a low computational cost compared to bio-inspired algorithms, which on
the case study analyzed, take up to 20 times longer. The operational evolution method converges on the same
global minimum as the genetic algorithm with higher accuracy.
The approximation of the support volume in a discrete way allows to calculate this variable to any
piece, regardless of its geometry, making this process automatic and simple, to comparison of its
mathematical formulation. The effectiveness of this approach is corroborated by a commercial 3D printing
software, where the regions needed for support printing correspond to the discrete support volume. Unlike
other research, non-symmetric geometries such as ‘Samsung stand’ are used, so the search surface is more
extensive and presents a unique global minimum. Finally, it is recommended to use optimization strategies in
the preprocessing phase in 3D printing, to select the best orientation to parts in which it is not possible
visually, allowing to reduce costs and time.
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Since the present proposed algorithm automatically selects the optimal print orientation, it seeks to
make a preprocessing software that offers the best part orientation to the user before printing his part. This
process ensures that it consumes less printing material, which is reflected in the cost and contamination in the
manufacturing process. In addition, the use of GPUs to parallelize the discrete objective function is proposed
since its computation time can be reduced with this strategy. Finally, it would be interesting to apply multi-
objective optimization techniques having more objective functions, such as the staircase effect, printing time
or surface finish, and other decision variables such as the printing pattern.
ACKNOWLEDGEMENTS
This paper is a research product from the IMP-ING-3122 high-impact project funded by the
Research Vice-Chancellor of Universidad Militar Nueva Granada–2021. Producto derivado del proyecto
IMP-ING-3122 financiado por la Vicerrectoría de Investigaciones de la Universidad Militar Nueva Granada
–Vigencia 2021.
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BIOGRAPHIES OF AUTHORS
Int J Elec & Comp Eng, Vol. 12, No. 6, December 2022: 5958-5966