A Method to Optimize the Part Build Orientation in Additive Manufacturing

The orientation of a part during manufacturing is a crucial variable that must be considered in product design to leverage the advantages of additive manufacturing (AM). Various methods for determining the optimal print direction have been proposed in the scientific literature, each based on different evaluation criteria. However, most existing studies focus on specific AM technologies and lack a comprehensive approach that incorporates multiple criteria. Additionally, these methods often require designers to assign weights to highly technical parameters, which can be difficult, particularly in the early stages of design. In contrast, designers are typically more comfortable with broader criteria such as cost-effectiveness, productivity, quality, mechanical strength, and environmental sustainability. This paper introduces a multi-criteria decision-making method to optimize part orientation in AM. The proposed approach evaluates six high-level decision criteria—cost-effectiveness, rapidity, productivity, quality, mechanical strength, and environmental sustainability—along with nineteen detailed technical sub-criteria. The Analytic Hierarchy Process (AHP) method prioritizes the high-level criteria. Instead, the Technique for Order of Preference by Similarity to the Ideal Solution (TOPSIS) determines the optimal build orientation.