An additive manufacturing system for additive manufacturing material with long fibers includes an extruder comprising a nozzle that includes a static-mixing portion, a compression portion, and a long fiber alignment portion. The static-mixing portion includes a static-mixing channel with static-mixing rods distributed inside and extending radially inward from a channel wall. The long fiber alignment portion has an alignment channel with a diameter D.sub.AC that is less than a diameter D.sub.SMC of the static-mixing channel. The compression portion includes with a reducing diameter from an input end to an output end of the compression channel. A nozzle and method for additive manufacturing are also disclosed.

An additive manufacturing system for an additive manufacturing material and embedded short-chopped fibers includes an extruder comprising a nozzle having a nozzle flow channel. The nozzle includes a plurality of spaced apart elongated aligning structures distributed inside the nozzle flow channel and parallel to the longitudinal center axis defining alignment flow channels within the nozzle flow channel. A nozzle for additive manufacturing, a method of additive manufacturing, and a method of making a nozzle for an additive manufacturing system for and additive manufacturing material and embedded short-chopped fibers are also disclosed.

Disclosed herein is a method of fabrication used in conjunction with simplified fabrication process such as sheet cutting or additive material manufacturing which can cure many deficiencies of laminar bonding or assembly processes including curing of micro-voids or delamination between layers of a component, as well as enabling the combination of components to form a more complex assembly. This method includes the steps of: providing a first component having been formed of a plurality of planar layers; providing a compaction vessel; providing a granular support medium to the interior of the compaction vessel; placing the first component into the granular support medium within the compaction vessel so as to fully encompass the first component or component assembly; heating the granular support and the primary component within the compaction vessel; and applying a compaction force so as to bond or re-fuse the planar layers together.