Fused Layer Modeling (FLM) is one of the most popular additive manufacturing techniques. Its application is often limited caused by the procedurally anisotropy. This work addresses FLM’s weakness by examining a new path planning concept that replaces printing several adjacent parallel lines, for example in perimeters. The new technique was compared with conventionally manufactured reference samples in tensile tension and three-point-bending tests. The results show an improvement of the tensile strength in build direction of the samples by up to 40% and a reduction of anisotropy by 28%.

Additive manufacturing offers a high degree of design freedom. When Design for Additive Manufacturing is conducted properly, lightweight potential can be exploited. This contribution introduces a novel design approach for the widespread fused layer modelling (FLM) technology when using orthotropic Fibre Reinforced Polymer filament. Its objective is to obtain stiff and strong load-path optimized FLM structures in a structured and algorithmic way. The approach therefore encompasses (1) build orientation optimization to consider weaker bonding between layers than intralayer; (2) topology optimization with orthotropic material properties to obtain favourable overall geometry and inner structure; (3) direct build path generation from optimized material orientation and alternatives to the direct generation and (4) simulation. The approach is demonstrated using a lift arm under multiple load cases and further demonstrator parts to show its general applicability. Lightweight potential of individual optimization steps and the influence of modifications contrasting general non-FLM-specific optimization are studied and discussed.