Considerations and selection of optimal orientation for different rapid prototyping systems

The ability to evaluate and determine the best part building orientation for different rapid prototyping (RP) processes is important for building a satisfactory part/prototype within the limits of manufacturing time and building cost. It is also an essential step towards the identification of the most suitable RP process with a given RP application. This paper discusses the selection of building direction for four RP processes, namely stereolithography (SL), selective laser sintering (SLS), fusion deposition modelling (FDM) and laminated object manufacturing (LOM). Main differences in the four processes are first examined with emphasis on the effects of these differences with regard to the building inaccuracy, the surface finish, the manufacturing time and cost. An optimal orientation algorithm is demonstrated on a part considered for processing with one of the four RP processes. The influence of the process characteristics on the selection of appropriate orientation with different RP processes is illustrated in the example.