Additive Manufacturing (AM) of continuous carbon fiber thermoplastic composites (CCFTC) enables the integrated manufacturing of lightweight, high-strength components, offering broad applications in aerospace, energy, and automotive industries. To further expand the applicability of this technology, it is essential to ensure the dimensional accuracy of the formed CCFTC components. In this study, we established an experimentally validated thermomechanical model using finite element analysis to predict and understand the dynamic temperature field and warpage generation during AM of CCFTC. The mechanism of warpage deformation was uncovered to guide the optimization of AM process for the warpage mitigation in the as-built components. The results showed that the warpage error between the simulated data and experimental results was less than 22%. To validate the understanding obtained, scalable manufacturing of an irregular CCFTC component on a high-throughput, multiple-degree-of-freedom robotic AM platform was performed to provide insights into the high-performance CCFTC component fabrication for practical applications.