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We present a field-based method of toolpath generation for 3D printingcontinuous fibre reinforced thermoplastic composites. Our method employs thestrong anisotropic material property of continuous fibres by generatingtoolpaths along the directions of tensile stresses in the critical regions.Moreover, the density of toolpath distribution is controlled in an adaptive wayproportionally to the values of stresses. Specifically, a vector field isgenerated from the stress tensors under given loads and processed to havebetter compatibility between neighboring vectors. An optimal scalar field iscomputed later by making its gradients approximate the vector field. Afterthat, isocurves of the scalar field are extracted to generate the toolpaths forcontinuous fibre reinforcement, which are also integrated with the boundaryconformal toolpaths in user selected regions. The performance of our method hasbeen verified on a variety of models in different loading conditions.Experimental tests are conducted on specimens by 3D printing continuous carbonfibres (CCF) in a polylactic acid (PLA) matrix. Compared to reinforcement byload-independent toolpaths, the specimens fabricated by our method show up to71.4% improvement on the mechanical strength in physical tests when using thesame (or even slightly smaller) amount of continuous fibres.

Field-Based Toolpath Generation for 3D Printing Continuous Fibre Reinforced Thermoplastic Composites