Stress-Driven G-Code Planning for Multi-Axis High-Speed Continuous Carbon Fiber 3D Printing

Continuous carbon fiber (CCF) 3D printing on multi-axis FFF systems can dramatically improve structural performance, but existing slicers ignore load-path alignment and generate suboptimal fiber trajectories. We present a G-code planning pipeline that integrates finite element analysis (FEA), SIMP topology optimization, and surface geodesic path planning to align fiber deposition along principal stress directions. Our XYA-axis motion planner generates helical winding and stress-aligned infill layers with a 16× G-code generation speedup over naive approaches. Parts printed with our planner exhibit significantly higher specific stiffness compared to standard rectilinear CCF toolpaths.