Composite filament 3d printing using complementary reinforcement formations

A method for printing a part with a three dimensional printer, the method comprising:

• receiving toolpath instructions having a plurality of single layer toolpaths encoded with first and second degrees of freedom,
• supplying a strand reinforced composite filament having reinforcing strands embedded in a flowable matrix;
• depositing consolidated composite swaths by:
• controlling a print head to output the strand reinforced composite filament with the reinforcing strands oriented parallel to a trajectory of the print head;
• controlling the print head to iron the strand reinforced composite filament to form consolidated composite swaths having reinforcing strands spread out against a surface;
• depositing a first consolidated composite swath according to a first single layer toolpath within a first layer;
• depositing a second consolidated composite swath according to a second single layer toolpath within the same first layer, the second consolidated composite swath having a crossing point with the first consolidated composite swath within the same first layer;
• and
• ironing the second consolidated composite swath to spread against the first consolidated composite swath.

A method for generating three-dimensional toolpath instructions for a three dimensional printer, the method comprising:

• receiving a three-dimensional geometry;
• slicing the three-dimensional geometry into layers;
• generating toolpath instructions to deposit consolidated composite swaths by ironing strand reinforced composite filament to form consolidated composite swaths having reinforcing strands spread out against a surface;
• generating toolpath instructions to deposit a first consolidated composite swath according to a first single layer toolpath within a first layer of the layers;
• generating toolpath instructions to deposit a second consolidated composite swath according to a second single layer toolpath within the same first layer, the second consolidated composite swath having a crossing point with the first consolidated composite swath within the same first layer;
• and
• generating toolpath instructions to iron the second consolidated composite swath to spread against the first consolidated composite swath within the same first layer.