Abstract: Fiber-reinforced thermoplastic honeycomb is prepared in a continuous manner one half cell at a time by laying down a corrugated web of thermoplastic, with and without fiber-reinforcement atop a honeycomb, selectively fusing the node-antinode demes and repeating the process until a honeycomb of the desired depth is prepared.

Abstract: A continuous, substantially uniform tow useful in forming composite molded articles is prepared by forming a continuous tow of continuous carbon fibers, forming a continuous tow of thermoplastic polymer fibers to a selected width, uniformly and continuously spreading the carbon fiber two to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow, intermixing the tows intimately, uniformly and continuously, in a relatively tension-free state, and continuosuly withdrawing the intermixed tow.

Abstract: A composite article is prepared by forming a continuous tow of continuous carbon fibers, forming a continuous tow of thermoplastic polymer fibers, uniformly and continuously spreading the thermoplastic polymer fibers to a selected width, uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow, intermixing the tows intimately, uniformly and continuously, in a relatively tension-free state, continuously withdrawing the intermixed tow and applying the tow to a mold and heating the tow.