Fast layer fiber orientation optimization method for continuous fiber-reinforced material extrusion process

Material extrusion (MEX) is an additive manufacturing process that uses thermoplastic layer-by-layer building. The use of continuous fiber-reinforced filament enhances mechanical properties, making MEX suitable for use in aerospace, automotive, and robotics industries. This study proposes a laminate optimization method to improve the stiffness of printed parts with low computing time. The 2D stress-flow-based method optimizes fiber’s orientation for each layer in the stacking direction, giving results for a 3D part optimization in a few minutes. Developed with Ansys Parametric Design Language, the computation tool was tested on printed wrenches, resulting in an 18% increase in stiffness. The proposed method is applicable to any printable shape.