Topological optimization and path planning for continuous fiber 3D-printed parts based on variable stiffness and fiber volume fraction

Abstract

This work presents a manufacturability‑driven topology optimization framework for continuous‑fiber 3D printing, where fiber orientation and density serve as design variables, and the fiber volume fraction is derived directly from manufacturable fiber paths. By computing the local fiber volume fraction from continuous‑fiber path planning, the method establishes a direct coupling between material distribution and feasible deposition trajectories. An equivalent stiffness model links fiber coverage to element properties, enabling iterative updates of both the structural response and the manufacturable fiber layout. Numerical studies demonstrate the effectiveness of the approach, and printed specimens further validate that the optimized designs achieve a substantial stiffness improvement over fixed‑fiber‑fraction counterparts.