System and method for additively manufacturing functional elements into existing components

1. A method of additively manufacturing a composite structure, comprising:

discharging from a first channel of a nozzle into a feature of an existing component a first track of material including a fiber wetted with a liquid matrix to form a bed;

simultaneously discharging from a second channel of the nozzle into the bed of the first track of material a second track of material including at least one of a wire and an optical fiber;

discharging from the nozzle at least one functional element connected between ends of the at least one of the wire and the optical fiber; and

exposing the liquid matrix to light during discharging to cure the liquid matrix and secure the at least one of the wire and the optical fiber within the feature,

wherein the first and second channels pass sequentially over the feature during movement of the nozzle over the existing component.

2. The method of claim 1 , further including:

mechanically detecting a spatial relationship between the nozzle and the feature; and

selectively adjusting a trajectory of the nozzle based on the spatial relationship.

3. The method of claim 1 , wherein discharging from the first channel of the nozzle the first track of material includes, riding a tip end of the nozzle along walls of the feature to cause excess liquid matrix to be drawn out of the nozzle.

4. The method of claim 3 , wherein an amount of the excess liquid matrix is about equal to 0-20% more liquid matrix than required to fully wet a fiber in the first track of material.

5. The method of claim 3 , wherein an amount of the excess liquid matrix is sufficient to coat the at least one of the wire and the optical fiber subsequently discharged into the bed of the first track of material.

6. The method of claim 1 , wherein the at least one functional element includes at least one of a resistor, a capacitor, a LED, a RFID tag, a switch, a battery, a fuse, and a filter.

7. The method of claim 6 , including forming the feature in the existing component.

8. The method of claim 7 , wherein forming the feature includes splitting a surface of the existing component.

9. The method of claim 7 , wherein forming the feature includes cutting away material from the existing component.

10. The method of claim 9 , wherein cutting away material includes detecting and cutting away material at a damaged area of the existing component.

11. The method of claim 1 , wherein:

discharging from the second channel of the nozzle onto the first track of material a second track of material including at least one of a wire and an optical fiber includes discharging at least one of a wire and an optical fiber having a first size; and

the method further includes simultaneously discharging from a third channel of the nozzle onto the second track of material a third track of material including at least one of a wire and an optical fiber having a second size.

12. The method of claim 11 , further including selectively cutting the at least one of the wire and the optical fiber in one of the second and third tracks of material.

13. The method of claim 12 , further including selectively retracting the at least one of the wire and the optical fiber in the one of the second and third tracks of material after cutting.

14. The method of claim 11 , further including moving a compactor over only the third track of material to compact each of the first, second, and tracks of material.

15. The method of claim 1 , further including compacting the first and second tracks of material.

16. A method of additively manufacturing a composite structure, comprising:

discharging from a first channel of a nozzle into a feature of an existing component a first track of material including at least a fiber wetted with a liquid matrix to form a bed;

simultaneously discharging from a second channel of the nozzle into the bed of the first track of material a second track of material including at least one of a wire and an optical fiber;

exposing the liquid matrix to light to cure the liquid matrix; and

while curing the liquid matrix, simultaneously discharging from the nozzle over the second track of material a third track of material including a thermoplastic.

17. The method of claim 16 , further including:

detecting a spatial relationship between the nozzle and the feature; and

selectively adjusting a trajectory of the nozzle based on the spatial relationship.

18. The method of claim 16 , wherein discharging from the nozzle into the first track of material the second track of material includes discharging at least one functional element connected between ends of the at least one of the wire and the optical fiber.

19. The method of claim 18 , wherein the at least one functional element includes at least one of a resistor, a capacitor, a LED, a RFID tag, a switch, a battery, a fuse, and a filter.

20. The method of claim 16 , further including forming the feature in the existing component.

21. The method of claim 16 , further including heating the thermoplastic prior to discharging the third track of material, wherein heating the thermoplastic including conducting heat from a heater associated with the third track of material into the liquid matrix in the first track of material to initiate a reaction in the liquid matrix.

22. A method of additively manufacturing a composite structure, comprising:

discharging from a first channel of a nozzle into a feature of an existing component a first track of material including a fiber wetted with a thermoset matrix;

simultaneously discharging from a second channel of the nozzle over the first track of material a second track of material including at least one of a wire and an optical fiber;

simultaneously discharging from a third channel of the nozzle over the second track of material a third track of material including a thermoplastic; and

heating the thermoplastic prior to discharging the third track of material, wherein heating the thermoplastic includes conducting heat from a heater associated with the third track of material into the thermoset matrix in the first track of material to initiate a curing reaction in the thermoset matrix,

wherein the first, second, and third channels pass sequentially over the feature during movement of the nozzle over the existing component.