A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.

A random mat material including fiber bundles, said fiber bundles including fibers having an average fiber length of 5 to 100 mm, and having an average number N of fibers in the fiber bundle that satisfies: $\frac{1.5{10}^5}{D^2}<N<\frac{4.5{10}^5}{D^2}$
wherein D is the average diameter of fibers in the fiber bundle, expressed in micrometers, and the standard deviation SD.sub.N of the number of fibers in a fiber bundle satisfies:
1,000<SD.sub.N<6,000
wherein at an end of the fiber bundle, the number of the fibers in a fiber bundle becomes less from center to edge of the fiber bundle in a fiber direction.

A random mat material including fiber bundles, said fiber bundles including fibers having an average fiber length of 5 to 100 mm, and having an average number N of fibers in the fiber bundle that satisfies: $\frac{1.5{10}^5}{D^2}<N<\frac{4.5{10}^5}{D^2}$
wherein D is the average diameter of fibers in the fiber bundle, expressed in micrometers, and the standard deviation SD.sub.N of the number of fibers in a fiber bundle satisfies:
1,000<SD.sub.N<6,000
wherein at an end of the fiber bundle, the number of the fibers in a fiber bundle becomes less from center to edge of the fiber bundle in a fiber direction.

A composite manufacturing method includes the step of drawing a nonwoven fabric formed of continuous fibers through a slurry of discontinuous fibers suspended in a dispersive liquid to yield a fiber-modified interlayer comprising a network of said discontinuous fibers attached to said nonwoven fabric.

A composite manufacturing method includes the step of drawing a nonwoven fabric formed of continuous fibers through a slurry of discontinuous fibers suspended in a dispersive liquid to yield a fiber-modified interlayer comprising a network of said discontinuous fibers attached to said nonwoven fabric.

A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.

A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.

Fiber-reinforced nonwoven composites having a wide variety of uses (e.g., leisure goods, aerospace, electronics, equipment, energy generation, mass transport, automotive parts, marine, construction, defense, sports and/or the like) are provided. The fiber-reinforced nonwoven composite includes a plurality of carbon fibers and a polymer matrix. The plurality of carbon fibers have an average fiber length from about 50 mm to about 125 mm. The fiber-reinforced nonwoven composite comprises a theoretical void volume from about 0% to about 10%.

Fiber-reinforced nonwoven composites having a wide variety of uses (e.g., leisure goods, aerospace, electronics, equipment, energy generation, mass transport, automotive parts, marine, construction, defense, sports and/or the like) are provided. The fiber-reinforced nonwoven composite includes a plurality of carbon fibers and a polymer matrix. The plurality of carbon fibers have an average fiber length from about 50 mm to about 125 mm. The fiber-reinforced nonwoven composite comprises a theoretical void volume from about 0% to about 10%.

A method of making a fibrous preform in carbon and/or fibres of a carbon precursor may include superposing at least two layers of carbon fibres and/or fibres of a carbon precursor according to a predefined superposition axis Z so as to form a multilayer body. The method may also include needle-punching via least one first needle-punching device the multilayer body in a needle-punching direction substantially parallel to the superposition axis Z to arrange at least part of the fibres parallel to the superposition axis Z, so as to obtain a needle-punched multilayer body. An optional step may include superposing with each other according to the superposition axis Z two or more of the needle-punched multilayer bodies, obtained separately by applying the above steps.