Additive Manufacturing (AM) provides the advantage of producing complex shapes that are not possible through traditional cutting processes. Along with this line, assembly-based part design in AM creates some opportunities for productivity improvement. This paper proposes an improved optimization algorithm for part separation (OAPS) in assembly-based part design in additive manufacturing. For a given object, previous studies often provide the optimal number of parts resulting from cutting processes and their corresponding orientation to obtain the minimum processing time. During part separation, the cutting plane direction to generate subparts for assembly was often selected randomly in previous studies. The current work addresses the use of random cutting planes for part separation and instead uses the hill climbing optimization technique to generate the cutting planes to separate the parts. The OAPS provides the optimal number of assemblies and the build orientation of the parts for the minimum processing time. Two examples are provided to demonstrate the application of OAPS algorithm.

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