Effect of continuous fibre printing orientation on the topology optimized 3D printed structures

Abstract This paper investigates the influence of printing orientations on topology optimization of structural components manufactured by Fused Filament Fabrication (FFF) with continuous fiber-reinforced filaments. These materials, known for their exceptional strength-to-weight ratio, enable the construction of efficient, lightweight structures, but exhibit significant anisotropy due to the directional properties of fibers. This anisotropy poses challenges in modeling the behavior of 3D-printed parts, particularly those designed via topology optimization. This paper uses Classical Lamination Theory (CLT) together with the Floating Projection Topology Optimization (FPTO) method to account for the directional behavior of each printed layer. The results show that the orientation of the fibers during printing strongly influences the final optimized topology, as well as its structural properties. Considerable variations in structural compliance are observed for varying printing orientations, which highlight the need to consider these factors when designing 3D-printed parts via topology optimization.