Methods for fiber reinforced additive manufacturing

A machine implemented method for generating motion command signals for controlling a three dimensional printer to form a plurality of layers of a 3D printed part, the method comprising acts of:

• generating a first toolpath signal for controlling the three dimensional printer to solidify fill material along a first toolpath that defines a wall of a first layer of the plurality of layers of the 3D printed part to be deposited;
• generating a second toolpath signal for controlling the three dimensional printer to lay a fiber tow along a second toolpath that defines a reinforcement region of the first layer of the 3D printed part to be deposited, the reinforcement region being interior to the wall;
• transmitting first motion command signals corresponding to the first toolpath signal to the three dimensional printer, the first motion command signals configured to control the three dimensional printer to solidify the fill material according to the first toolpath to form the wall of the first layer of the 3D printed part;
• and
• transmitting second motion command signals corresponding to the second toolpath signal to the three dimensional printer, the second motion command signals configured to control the three dimensional printer to lay the fiber tow according to the second toolpath and orient the fiber tow such that the reinforcement region of the first layer of the 3D printed part exhibits anisotropic strength in a specific direction corresponding to a trajectory of the second toolpath.

A 3D printer for additive manufacturing a 3D printed part including a plurality of layers, the 3D printer comprising:

• at least one printer head configured to be coupled to a supply of fill material and a fiber supply including a fiber tow;
• a build platen configured to support the 3D printed part;
• a motorized drive configured to move at least one of the at least one printer head and the build platen;
• and
• a controller configured to operate the motorized drive and the at least one printer head to build the 3D printed part by:
• solidifying the fill material along a first toolpath that defines a wall of a first layer of the plurality of layers of the 3D printed part;
• laying the fiber tow along a second toolpath that defines a reinforcement region of the first layer of the 3D printed part, the reinforcement region being interior to the wall;
• and
• orienting the fiber tow such that the reinforcement region of the first layer of the 3D printed part exhibits anisotropic strength in a specific direction corresponding to a trajectory of the second toolpath.