Fiber and stress consistency of 3D printed continuous fiber reinforced composite topology structures

作者：Zhengxian Guo, Dingxing Zhi, Zhanghao Hou, Meng Luo, Aotian Dong, Xin Wang, Xinying Shao, Xiaoyong Tian · 发表于：Additive Manufacturing Frontiers · 年份：2026 · DOI：10.1016/j.amf.2026.200376 · 研究领域：Topology Optimization in Engineering、Composite Material Mechanics、Cellular and Composite Structures

The 3D printing of continuous fiber reinforced composites (CFRCs) provides a novel approach for the design and fabrication of lightweight topological composite structures. Achieving a high level of consistency between fiber orientation and stress distribution is critical for enhancing the mechanical performance of 3D printed CFRCs. Accordingly, this study employs a topology optimization method based on variable density for structural design, and achieves integrated forming of the composite topology through continuous fiber path planning. To quantitatively evaluate the matching degree between fiber and stress, a quantitative analysis method was established to systematically investigate the consistency between fiber orientation and stress direction, as well as between fiber content and stress magnitude. The optimized CFRCs topological structures were fabricated via 3D printing. Combined with experimental testing and failure analysis, the influence of the topological configuration on fiber orientation and stress distribution was explored. This study demonstrates that after optimization, the minimum consistency coefficient ε min increased to 3.45 times that before optimization, and the Pearson correlation coefficient r increased by 0.72. The fiber-stress collaborative design method has promising applications in the development of composite components in fields such as aerospace and rail transportation.