Globally continuous hybrid path for extrusion-based additive manufacturing

In extrusion-based additive manufacturing, path filling patterns may significantly affect the printing process. To overcome printing defects incurred by path discontinuity, a Globally Continuous Hybrid Path (GCHP) is developed to solidly fill or partially fill connected domains. Discontinuous contour paths and single zigzag paths are constructed to generate locally continuous paths. These paths are subsequently connected by contour paths to render global continuity. To reduce underfilled areas without breaking path continuity, the boundaries of gap areas are evenly clipped and merged with the path. Sharp turns are optimized by fillet edges to alleviate the reduction in printing velocity. The construction results of variable shapes indicate that GCHP can continuously fill domains. The printing quality and mechanical performance of the proposed path are better than those of the previous scheme based on contour parallel paths. This study paves a new way to fabricate models using hybrid paths for extrusion-based additive manufacturing. • A Globally Continuous Hybrid Path (GCHP) is proposed for additive manufacturing. • Printing defects incurred by path breakpoints can be solved by GCHP. • The GCHP can implement solid and partial infill result for connected domains. • Samples using GCHP exhibit superior printing quality and mechanical property.