Additive manufacturing technology is often used to manufacture complex structures. With this technology, continuous fibers can be printed flexibly. In this study, a grid filling method for 3D printing continuous carbon fibers is proposed. This method enables the carbon fibers to obtain a good orientation by changing the relevant parameters of the sinusoidal curve. A grid filling structure composed of multiple sinusoidal curves was designed, which could freely set the number of the curves. The sinusoidal grid can be further optimized using a variable-density method, which can adjust the grid density based on stress distribution. The test results indicate that the variable-density method can effectively enhance the sinusoidal grid structures. This path planning method provides more possibilities for 3D printing of continuous carbon fiber composite structures.
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