Optimization of build orientation in additive manufacturing: a comparative evaluation of algorithms and critical review

The study investigates the optimization of build orientation in additive manufacturing, an influential factor affecting mechanical properties, surface and part quality, and process efficiency. Two orientation evaluation strategies are compared: the commercial software Autodesk Netfabb and a novel multi-criteria algorithm developed at RWTH Aachen University. The proposed algorithm is designed to minimize thermally induced deformation during printing with Powder Bed Fusion – Laser Beam Melting technology. It employs six Key Performance Indicators (KPIs) derived from part geometry, which are evaluated on a layer-by-layer basis to assess deformation risk. While the study identifies correlations between geometric KPIs, the orientation ratings generated by the algorithm exhibit inconsistencies and limited reliability. The method is benchmarked against Autodesk Netfabb’s commercial orientation tool, which utilizes a multi-objective optimization approach, using a shared dataset of test parts. The critical comparison highlights the respective strengths and limitations of both approaches and proposes directions for future methodological improvements in defining build orientation.