Balancing Strength and Finish: A Multi-Objective Evolutionary Optimization Framework for Additive Manufacturing Process Parameters

DOI

10.2991/978-94-6239-750-7_17How to use a DOI?

Keywords

Additive manufacturing; selective laser melting; multi-objective optimization; surface roughness; mechanical strength; NSGA-II; response surface methodology

Abstract

Additive Manufacturing (AM) has transformed conventional manufacturing through layer-wise fabrication of complex geometries while reducing material waste. However, limitations in mechanical strength and surface finish continue to restrict its use in safety-critical engineering applications. This research investigates a multi-objective optimization framework for improving the mechanical performance and surface quality of AM components. Selective Laser Melting (SLM) is selected as the primary process due to its widespread industrial adoption. Experimental parameters such as laser power, scan speed, hatch spacing, layer thickness, and build orientation are considered critical control factors. A hybrid optimization approach integrating Response Surface Methodology (RSM) and a Non-Dominated Sorting Genetic Algorithm II (NSGA-II) is developed to identify optimal parametric combinations. Tensile strength, surface roughness (Ra), and density are chosen as performance indicators. The proposed optimization framework demonstrates significant improvements: tensile strength increased by 12–18%, and surface roughness decreased by 20–35% compared to baseline builds. The results confirm the feasibility of systematic parameter tuning to enhance AM functionality and reliability across aerospace and biomedical engineering contexts.

Copyright

© 2026 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - Siddharth Singh
AU  - Sunil Sahai
AU  - Kriti Srivastava
PY  - 2026
DA  - 2026/08/31
TI  - Balancing Strength and Finish: A Multi-Objective Evolutionary Optimization Framework for Additive Manufacturing Process Parameters
BT  - Proceedings of the International Conference on Advanced Design, Manufacturing, and Sustainable Energy Systems (ICADMSES 2026)
PB  - Atlantis Press
SP  - 221
EP  - 235
SN  - 2589-4943
UR  - https://doi.org/10.2991/978-94-6239-750-7_17
DO  - 10.2991/978-94-6239-750-7_17
ID  - Singh2026
ER  -