Abstract: A method of forming a pultruded shaped composite material comprising carbon fiber having a diameter not greater than 0.001 inch aligned linearly with a degree of waviness defined by an average amplitude to length (A/L) ratio of less than 0.9 percent in a matrix is formed around the fiber and solidified or cured into a rigid form that will not melt during subsequent processing steps to prevent an increase in waviness during subsequent processing steps. The compressive strength of the composite material approaches the tensile strength of the material. The matrix material consists essentially of a resin present in the range of about 10 to 50 percent by volume of the composite material. The A/L ratio is determined by measuring the distribution of angularity found in the aligned carbon fibers in a selective cross section cut at five degrees to the fiber plane, wherein the standard deviation for a 300 sample angularity measurement is not greater than 0.88 degrees.

Abstract: A pultruded shaped composite material of carbon fiber having a diameter not greater than 0.001 inch aligned linearly with a degree of waviness defined by an average amplitude to length (A/L) ratio of less than 0.9 percent, the matrix formed around the fiber and solidified or cured into a rigid form that will not melt during subsequent processing steps to prevent an increase in waviness during subsequent processing steps. The matrix material consists essentially of a resin present in the range of about 10 to 50 percent by volume of the composite material. The A /L ratio is determined by measuring the distribution of angularity found in the aligned carbon fibers in a selective cross section cut at five degrees to the fiber plane, wherein the standard deviation for a 300 sample angularity measurement is not greater than 0.88 degrees.