This paper proposes an integrated approach to determine optimal build orientation for powder bed fusion by laser (PBF-L), by simultaneously optimizing mechanical properties, surface roughness, the amount of support structure (SUPP), and build time and cost. Experimental data analysis has been used to establish the objective functions for different mechanical properties and surface roughness. Geometry analysis of the part has been used to estimate the needed SUPP and thus evaluate the build time and cost. Normalized weights are assigned to different objectives depending on their relative importance allowing solving the multi-objective optimization problem using a genetic optimization algorithm. A study case is presented to demonstrate the capabilities of the developed system. The major achievements of this work are the consideration of multiple objectives and the establishment of objective function considering different load direction and heat treatments. A user-friendly graphical user interface was developed allowing to control different optimization process factors and providing different visualization and evaluation tools.

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