Additively manufactured composite heater

1. A heating element, comprising:

a matrix material;

an electrically and thermally conductive fiber that is at least partially encased in the matrix material; and

an electrically conductive fiber that extends into the matrix material and connects with the electrically and thermally conductive fiber,

wherein a resistance of the electrically and thermally conductive fiber is higher than a resistance of the electrically conductive fiber.

2. The heating element of claim 1 , wherein the matrix material is a thermoset polymer.

3. The heating element of claim 1 , wherein the electrically and thermally conductive fiber is continuous throughout the matrix material.

4. The heating element of claim 3 , further including electrically and thermally conductive particles suspended in the matrix material.

5. The heating element of claim 1 , wherein the electrically and thermally conductive fiber includes only particles suspended in the matrix material.

6. The heating element of claim 1 , wherein the matrix material has a porosity less than about 60%.

7. The heating element of claim 1 , wherein:

the electrically and thermally conductive fiber is a first fiber; and

the heating element further includes a second electrically and thermally conductive fiber that is at least partially encased in the matrix material and connected to the electrically conductive fiber.

8. The heating element of claim 7 , wherein:

the first fiber forms a first circuit; and

the second electrically and thermally conductive fiber forms a second circuit.

9. The heating element of claim 7 , wherein:

the first fiber is joined serially with the second electrically and thermally conductive fiber; and

the second electrically and thermally conductive fiber has at least one of a diameter, cross-sectional shape, and material consist that is different from the first fiber.

10. The heating element of claim 9 , further wherein the first fiber is joined with the second electrically and thermally conductive fiber via a solder paste.

11. A composite heater, comprising:

a base additively manufactured from a first matrix material;

a heating element additively manufactured adjacent the base from a second matrix material and an electrically and thermally conductive fiber that is at least partially encased in the second matrix material; and

a control mechanism configured to selectively complete a circuit between a power supply and the electrically and thermally conductive fiber.

12. The composite heater of claim 11 , wherein a thermal conductivity of the first matrix material is lower than a thermal conductivity of the second matrix material.

13. The composite heater of claim 12 , wherein:

the first matrix material has a porosity greater than about 60%; and

the second matrix material has a porosity less than about 60%.

14. The composite heater of claim 12 , wherein the electrically and thermally conductive fiber is continuous throughout the second matrix material.

15. The composite heater of claim 14 , further including electrically and thermally conductive particles suspended in the second matrix material.

16. The composite heater of claim 12 , wherein the electrically and thermally conductive fiber includes only particles suspended in the second matrix material.

17. The composite heater of claim 11 , wherein:

the base includes a recess; and

the heating element is disposed in the recess.

18. The composite heater of claim 11 , wherein the base is additively manufactured from a continuous fiber that is at least partially encased in the first matrix material and formed into a lattice structure.

19. The composite heater of claim 11 , wherein the base is additively manufactured from a continuous fiber that is at least partially encased in the first matrix material and formed into an electromagnet.

20. The composite heater of claim 11 , wherein the first and second matrix materials are thermoset polymers.