Chopped fiber composite systems and methods are disclosed. Sorting systems include a conveyor, an imager, a plurality of receptacles, a pneumatic device, and controller. Molding systems include a conveyor, an imager, a mold, a pneumatic device, and a controller. The controller directs the pneumatic device to alter the freefall of chopped fiber composite pieces based on characteristics of the chopped fiber composite pieces as they drop from the conveyor and into a receptacle or a mold. Sorting and molding methods include dropping chopped fiber composite pieces, detecting characteristics of the dropping pieces, and directing the pieces based on the detected characteristics.

A method for manufacturing a composite product, including: 1) preparing a composite powder including 10-50 v. % of a polymer adhesive and 50-90 v. % of a chopped fiber; 2) shaping the composite powder by using a selective laser sintering technology to yield a preform including pores; 3) preparing a liquid thermosetting resin precursor, immersing the preform into the liquid thermosetting resin precursor, allowing a liquid thermosetting resin of the liquid thermosetting resin precursor to infiltrate into the pores of the preform, and exposing the upper end of the preform out of the liquid surface of the liquid thermosetting resin precursor to discharge gas out of the pores of the preform; 4) collecting the preform from the liquid thermosetting resin precursor and curing the preform; and 5) polishing the preform obtained in 4) to yield a composite product.

A method of processing a carbon fiber tow includes the steps of providing a carbon fiber tow made of a plurality of carbon filaments, depositing a sizing composition at spaced-apart sizing sites along a length of the tow, leaving unsized interstitial regions of the tow, and cross-cutting the tow into a plurality of segments. Each segment includes at least a portion of one of the sizing sites and at least a portion of at least one of the unsized regions of the tow, the unsized region including and end portion of the segment.

A method of processing a carbon fiber tow includes the steps of providing a carbon fiber tow made of a plurality of carbon filaments, depositing a sizing composition at spaced-apart sizing sites along a length of the tow, leaving unsized interstitial regions of the tow, and cross-cutting the tow into a plurality of segments. Each segment includes at least a portion of one of the sizing sites and at least a portion of at least one of the unsized regions of the tow, the unsized region including and end portion of the segment.

A textile product and a method of manufacturing a composite object therefrom includes interacting a granular material with a textile material, with the textile material impregnated with the elements of the granular material forming a textile product, and introducing the textile product into a molding process so as to form the composite object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.

A textile product and a method of manufacturing a composite object therefrom includes interacting a granular material with a textile material, with the textile material impregnated with the elements of the granular material forming a textile product, and introducing the textile product into a molding process so as to form the composite object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.

A method for forming a composite component, comprising: locating a rigid composite element comprising a matrix interspersed with long fibre reinforcement in a mould that is shaped to define a cavity about the rigid element; loading a material comprising a matrix precursor interspersed with short fibre reinforcement into the cavity; and curing the matrix precursor.

A method for forming a composite component, comprising: locating a rigid composite element comprising a matrix interspersed with long fibre reinforcement in a mould that is shaped to define a cavity about the rigid element; loading a material comprising a matrix precursor interspersed with short fibre reinforcement into the cavity; and curing the matrix precursor.

Fibers, prepreg materials, compositions, composite articles, and methods of producing composite articles are disclosed herein. A fiber may include at least one polymeric fiber and a plurality of carbon nanotubes. The at least one polymeric fiber extends in a lengthwise direction. The at least one polymeric fiber is a nanofiber.

Fibers, prepreg materials, compositions, composite articles, and methods of producing composite articles are disclosed herein. A fiber may include at least one polymeric fiber and a plurality of carbon nanotubes. The at least one polymeric fiber extends in a lengthwise direction. The at least one polymeric fiber is a nanofiber.