Adaptive variable layer thickness and perimetral offset planning for layer-based additive manufacturing processes

Abstract

ABSTRACT This paper presents a methodology to estimate and optimize the process of slicing for a layer-based additive manufacturing process. An objective function for optimizing the process planning parameters is proposed in which perimetral offsets for each layer are considered as a parameter in addition to the layer thickness. The root-mean-square (RMS) value of the deviations between the NURBS representation of the CAD model and its built-up simulation is suggested to estimate a quantitative measure for the uncertainties. The proposed approach eliminates the sophistication of the calculation cusp volume in 3D space and has more compatibility with the corresponding inspection processes. The developed methodology is introduced based on using a metaheuristic algorithm to find the optimal layer thicknesses and perimetral offsets for a built-up model. A data collecting approach is also introduced to reduce the computation time associated with the simulation of the build-up model at each iteration. The developed methodology potentially can be used for layer-based additive manufacturing processes