A composite structure includes a number of fiber layers. Each fiber layer of the number of fiber layers includes a fiber bundle and a filament layer at least partially covering the fiber bundle. The filament layer includes discontinuous filaments. The discontinuous filaments include at least one of different length filaments, including first length filaments and second length filaments. The first length filaments include a first length and the second length filaments include a second length. The first length is different than the second length. The discontinuous filaments include at least one of different type filaments, including first type filaments and second type filaments. The first type filaments include a first material composition. The second type filaments include a second material composition. The first material composition is different than the second material composition. The composite structure includes a resin binding the number of fiber layers together.

A composite structure includes a number of fiber layers. Each fiber layer of the number of fiber layers includes a fiber bundle and a filament layer at least partially covering the fiber bundle. The filament layer includes discontinuous filaments. The discontinuous filaments include at least one of different length filaments, including first length filaments and second length filaments. The first length filaments include a first length and the second length filaments include a second length. The first length is different than the second length. The discontinuous filaments include at least one of different type filaments, including first type filaments and second type filaments. The first type filaments include a first material composition. The second type filaments include a second material composition. The first material composition is different than the second material composition. The composite structure includes a resin binding the number of fiber layers together.

A method includes providing a reservoir of randomly oriented fibers in a solution, dispensing the solution of randomly oriented fibers through a nozzle having an orientation component onto a porous substrate as a solution of aligned fibers, and immobilizing the fibers to form a fiber pre-form. A system includes a porous substrate, a deposition nozzle, a reservoir of randomly oriented fibers in solution connected to the deposition nozzle, the deposition nozzle position adjacent the porous substrate and connected to the reservoir, the nozzle to receive the randomly oriented fibers and output aligned fibers, and a vacuum connected to the porous substrate to remove fluid from the porous substrate as the deposition nozzle deposits the aligned fibers on the porous substrate to produce a fiber pre-form having aligned fibers.

A method includes providing a reservoir of randomly oriented fibers in a solution, dispensing the solution of randomly oriented fibers through a nozzle having an orientation component onto a porous substrate as a solution of aligned fibers, and immobilizing the fibers to form a fiber pre-form. A system includes a porous substrate, a deposition nozzle, a reservoir of randomly oriented fibers in solution connected to the deposition nozzle, the deposition nozzle position adjacent the porous substrate and connected to the reservoir, the nozzle to receive the randomly oriented fibers and output aligned fibers, and a vacuum connected to the porous substrate to remove fluid from the porous substrate as the deposition nozzle deposits the aligned fibers on the porous substrate to produce a fiber pre-form having aligned fibers.

Provided are a molded body and a method for manufacturing a molded body, the molded body comprising: reinforced fibers having a weight average fiber length of 1 mm or more and 100 mm or less: and a thermoplastic resin, wherein the molded body is provided with a first main shape surface part, a second main shape surface part connected to the first main shape surface part in a crossing state, and a connection surface part connected to both the first main shape surface part and the second main shape surface part, the connection surface part protrudes from the first main shape surface part and the second main shape surface part on a valley side formed by the first main shape surface part and the second main shape surface part, and reinforced fibers are continuously dispersed in an in-plane direction at a boundary region between the first main shape surface part and the connection surface part and a boundary region between the second main shape surface part and the connection surface part.

Provided are a molded body and a method for manufacturing a molded body, the molded body comprising: reinforced fibers having a weight average fiber length of 1 mm or more and 100 mm or less: and a thermoplastic resin, wherein the molded body is provided with a first main shape surface part, a second main shape surface part connected to the first main shape surface part in a crossing state, and a connection surface part connected to both the first main shape surface part and the second main shape surface part, the connection surface part protrudes from the first main shape surface part and the second main shape surface part on a valley side formed by the first main shape surface part and the second main shape surface part, and reinforced fibers are continuously dispersed in an in-plane direction at a boundary region between the first main shape surface part and the connection surface part and a boundary region between the second main shape surface part and the connection surface part.

In-aircraft seats include plastic components having anti-microbial, metallic reinforcing fibers such as copper or silver. Copper or silver wires are embedded into the plastic at the time or molding to provide both structural reinforcement and anti-microbial properties. At the time of molding, copper or silver wires are disposed in a plastic mold prior to plastic application to ensure the metallic wires are generally disposed toward the surface of the molded part.

In-aircraft seats include plastic components having anti-microbial, metallic reinforcing fibers such as copper or silver. Copper or silver wires are embedded into the plastic at the time or molding to provide both structural reinforcement and anti-microbial properties. At the time of molding, copper or silver wires are disposed in a plastic mold prior to plastic application to ensure the metallic wires are generally disposed toward the surface of the molded part.

Suspending fibers within a substantially similar direction within flow field allows for an even dispersion of fibers in a manufactured composite. The flow field can be established within a resin tank so as to control orientation of the fibers. An advantage of this approach is that fiber orientation can be changed layer by layer during printing. No matter where the reinforcements need to be, the fibers can be aligned on the fly to accommodate. 3D prints can made stronger for a very wide range of objects and opportunities.

An extrusion system including an extruder screw housed in a barrel, a nozzle heater coupled to the barrel, a printing nozzle coupled to the nozzle heater, and a randomizing element at least partially in the printing nozzle. The randomizing element is configured to randomize the orientation of fiber elements and/or fillers in an extrusion melt traveling through the extrusion system. Increasing the randomization of the fiber orientations in the melt composition improves the physical and thermal properties of a printed bead printed by the extrusion system.