Multi-layer continuous carbon fiber pattern optimization and a spline based path planning interpretation

TL;DR

This paper introduces a method for optimizing fiber patterns in 3D printing of continuous carbon fiber composites, combining linear optimization for layer design with spline-based path planning for manufacturing.

Contribution

It presents a novel integrated approach for designing layer-specific fiber patterns and interpreting them through spline-based paths, improving manufacturability and structural integrity.

Findings

Optimized fiber patterns ensure load-bearing connections.

Spline-based path planning interprets fiber layouts effectively.

The method accommodates layer-specific variations.

Abstract

A novel approach for creating tool paths for continuous carbon fiber-reinforced thermoplastic 3D printing is introduced. The aim is to enable load-bearing connections while avoiding non-manufacturable crossings of paths by generating layer specific patterns. We require a graph representation of the structural design with given desired continuous fiber connections. From this, optimal fiber patterns are obtained for each printing layer by solving linear integer optimization problems. Each layer may have a unique solution based on the history of the previous layers. Additionally, a path planning approach is presented which interprets the obtained layers via curves based on quadratic and cubic B\'ezier splines and their offset curves in constant distance. The single parameter for the construction of the paths is the minimal turning radius of the fibers. The path planning provides a new interpretation for the final geometry of the design to be printed.