Abstract
This study presents algorithms for additively manufacturing semi-woven carbon fiber composite skins over singly and doubly curved non-planar surfaces through an innovative remapping/wrapping algorithm. The algorithm efficiently generates 5-axis continuous fiber deposition paths from 2D fiber layout patterns in a way that reduces geometric distortion in fiber placement that normally occurs when planar 2D toolpaths are linearly projected onto non-planar surfaces. A customized 5-axis 3D printer equipped with a modified continuous carbon fiber deposition head is used to validate feasibility of the algorithm by printing a semi-woven carbon fiber skin onto a hemi-spherical surface. Toolpaths are smoothened prior to printing to reduce jerking motions in the 5-axis machine's A/B axes.