Performance Deviations in 3D-Printed Continuous Carbon Fiber Reinforced Structures by Anisotropic Topology Optimization

This research study investigates the performance drop from idealized designs derived through novel tensor-based topology optimization processes to physically manufactured structures. The L-shaped beam problem is analyzed using a new print path technique inspired by the biological rationale of the Swift-Hohenberg equation, and the print path performance is compared and assessed with other benchmark problems including the cantilever and the Messerschmitt–Bölkow–Blohm beams (MBB). Key challenges in additively manufactured continuous carbon fiber reinforced polymers are addressed, particularly the effects of tight curvatures and print path design choices. Experimental specimens were analyzed using digital image correlation and compared with Finite Element Method (FEM) predictions to assess stiffness retention and performance discrepancies. Two generations of print paths for the L-shaped beam were developed and tested, with their experimental performance compared to the idealized topology-optimized design.