Abstract: Fiber reinforced matrix materials, wherein the fiber is of balanced tensile to ductile properties, and the molecular orientation of the fiber is substantially similar to the molecular orientation of a fiber precursor from which the fiber is formed; and wherein the fiber comprises a flattened shank having first and second terminal ends, wherein the first terminal end comprises a first nodule, and the second terminal end comprises a second nodule; and wherein a cross sectional area of the flattened shank is less than a cross sectional area of the first nodule, and wherein the cross sectional area of the flattened shank is less than a cross sectional area of the second nodule; and wherein the first nodule and second nodule retain the approximate diameter of a precursor material from which the fiber is formed.

Abstract: This specification discloses fiber additives for reinforcing matrix materials and an apparatus for forming the same, said fibers having flattened shanks terminated with egg-shaped nodules. The apparatus comprises a roller-former-cutter assembly that forms the fibers in a single operation from continuous filaments using compressive force and a unique cut-out and blade assembly. The fibers described are designed to have an increased pull-out resistance compared to other fiber morphologies.