Part orientation optimization for Wire and Arc Additive Manufacturing process for convex and non-convex shapes

Building orientation optimization for Additive Manufacturing (AM) process is a crucial step because it has a vital effect on the accuracy and performance of the created part. Wire and Arc Additive Manufacturing’s (WAAM) working space is less limited, and the production time is significantly shorter than the other metal 3D printers. However, one of the adverse effects of WAAM is the defect at the start and endpoints of the welding beads. In this paper, an algorithm has been invented to define the optimal printing position, reducing the number of these defects by rotating the 3D object in a loop around the X and Y axes by a small constant degree and then selecting the degree of rotation that has the fewest uninterrupted surfaces and the largest area of the first layer. The welding process will be interrupted as little as possible by the torch if there are the fewest possible uninterrupted surfaces. As a result, there will be fewer defects in the production and finishing of the welding beads. In order to have a sufficient connection surface with the build tray, which will aid in holding the workpiece in place, the largest first layer should also be sought. Therefore, it has been found that a properly defined orientation relative to the build tray can reduce the number of uninterrupted surfaces within the layers, which will improve the expected dimensional accuracy of the parts. The efficiency of the process is highly affected by the shape of the part, but in most cases, the print errors can be drastically minimized.