Curved-Layer Slicing and Continuous Path Planning for Multi-Axis Printing of Fiber-Reinforced Composite Structures

Fiber-reinforced composite (FRC) additive manufacturing technologies have successfully overcome the limitations of traditional autoclave forming, offering significantly enhanced design freedom. However, one of the remaining key challenges is the planning of continuous printing paths that align with a defined fiber orientation vector field within FRC structures. This paper introduces a comprehensive framework for multi-axis curved-layer printing of 3D FRC parts. First, a novel multi-axis curved-layer slicing method based on deformed space mapping is proposed. This approach ensures that the sliced curved layers are as parallel as possible to the intended fiber orientations, improving the alignment between the printing process and fiber direction. Next, a vector field-driven printing path planning method for each curved layer is developed, which guarantees that the generated printing paths conform to the specified fiber orientations while also ensuring continuous material deposition. Additionally, a new algorithm for generating support structures tailored to curved layers is proposed, preventing material collapse during the printing process. The effectiveness of the proposed slicing method, path planning, and support structure generation are validated through extensive experiments and simulations, demonstrating their potential to significantly improve the performance and versatility of FRC additive manufacturing.