An interlayer interleaved hybrid path to optimize performance of material extrusion additive manufacturing

The rapid expansion of material extrusion additive manufacturing (MEAM) has emphasized the importance of path-planning strategies for enhancing manufacturing efficiency and printing quality. However, current strategies are often deemed inefficient, inadequately adaptive, and mechanically weak. Additionally, existing studies generally overlook interlayer dissimilarity, leading to connected voids. To address these challenges, this paper proposes a novel multi-level hybrid path-planning strategy with an interlayer interleaving property. This approach utilizes a planar geometric processing algorithm that fills a pattern with inward-contour-parallel and zigzag paths, ensuring homogeneity and compactness. Global continuity is achieved through bridging paths based on curve containment, while a partitioning process based on medial-axis extraction minimizes defects between layers. Numerical and experimental results demonstrate that the proposed tool-path exhibits enhanced contour adaptability, integrity, and mechanical performance compared to common tool-paths. The study also analyses how tool-path planning influences the strength, ductility, and failure modes of specimens, providing valuable insights for MEAM and construction of durable and aesthetically pleasing buildings.