Integrating Orientation Optimization and Thermal Distortion Prediction in LPBF: A Validated Framework for Sustainable Additive Manufacturing

This study investigates the impact of build orientation on thermal distortion, residual stress behaviour, and process efficiency in LPBF. Four orientation strategies, optimized for surface area, support volume, print time, and overheating, were generated in Siemens NX and evaluated using Atlas 3D to predict build-stage and post-support removal distortion. Experimental validation through 3D scanning enabled detailed surface deviation comparisons with simulation outputs. Results showed that support volume and print time optimizations led to the lowest in-process distortion but exhibited higher deformation after support removal, driven by residual stress relaxation. In contrast, the surface area-optimized orientation displayed greater distortion during printing but more stable post-processing behaviour. The overheating-optimized build resulted in the largest total distortion. Atlas 3D predictions aligned closely with scan data, particularly in identifying critical zones on sloped and unsupported surfaces. Sustainability and cost analysis revealed that the surface area strategy had the highest impact in reducing CO₂ emissions and production costs (~€832 and ~900 g CO₂/part), while support volume and print time orientations reduced cost by more than 20% and halved emissions. Energy consumption followed the same trend, with support volume and print time optimisations requiring only ~2 kWh/part compared to nearly 5 kWh/part for surface area, and overheating minimisation. These findings underscore the importance of integrating distortion simulation, cost, and environmental criteria into orientation selection to achieve balanced, high-performance LPBF manufacturing.