Abstract: A process for cutting a multi-filament tow into fibers of ultra-short length and narrow size distribution is provided. Initially, a multi-filament tow is passed through a bath of liquid impregnating material at elevated temperature. The impregnated tow is then passed through a die which is sized to control the quantity of material impregnating the tow and to compact the filaments of the tow into a closely packed bundle. The resulting tow is then cooled to solidify the impregnating material and to convert the tow to a rigid form. The rigid tow is then cut, yielding wafer-thin disks. The impregnating material is then stripped from the wafer-thin disks with a solvent followed by removal of the solvent, thereby yielding fibers of ultra-short length and narrow size distribution.