Abstract
The main idea behind this paper is to highlight efforts made to improve the application potential of the fused deposition modelling (FDM) process by producing the rapid prototyping parts at minimum cost. Build orientation analysis for prismatic, curved boundary, and complex-shaped parts is carried out. The mathematical model is formulated to estimate the total cost of part preparation in FDM. Optimal part build orientation and the values of parameters resulting in the minimum total cost of parts preparation are identified. The parts produced by the FDM rapid prototyping process are considered for build orientation analysis. The concept can be extended for parts produced with any layered manufacturing process. This is the first attempt to deal with diversified types of part geometries and formulate a universal cost model applicable for all types of parts to determine minimum cost in FDM.