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The development of additive manufacturing (AM) has created more opportunities for fabricating complex topology and fiber distributions, which are essential for fully exploiting the performance benefits and design flexibility of continuous fiber-reinforced polymers (CFRP). However, the complexity of the geometry and fiber orientation in CFRP structures poses challenges for multi-scale optimization and their direct application in AM. This paper develops a multi-scale collaborative optimization method for CFRP structures. A compliance minimization model with structural volume constraint is constructed to simultaneously optimize the topology and local fiber distribution. To address the critical issue of fiber discontinuity in optimized designs, we propose an improved fiber orientation filtering strategy that enforces smooth and continuous fiber distributions, thereby enhancing both structural performance and manufacturability. Building upon this optimization foundation, we introduce a complementary fiber path planning algorithm that translates the optimized fiber orientation fields into continuous, collision-free printing paths suitable for AM processes. Numerical examples and experimental validation are conducted to assess the validity and robustness of the developed method, wherein the fabricated specimens with complementary fiber paths exhibit substantial improvements in structural stiffness and load-bearing capacity relative to conventional path planning strategies. Collectively, this work establishes a unified paradigm bridging multiscale optimization design with manufacturing-oriented path planning, thereby offering a robust and scalable pathway toward performance-driven design of additive manufactured CFRP structures.

Continuous fiber-reinforced polymers, Topology optimization, Fiber orientation optimization, Additive manufacturing, Fiber path planning