Abstract: An improved method for producing and processing deregistered and disorientated synthetic tow for forming fiber filled articles in which crimped registered tow is deregistered through pairs of rolls utilizing a non-continuous groove-threaded surface. The synthetic tow is dispersed and spread, and collected for continuous distribution into and envelopment by article surface material. The automatic process and apparatus associated therewith additionally form and finish the fiber filled articles themselves for additional fabrication processes or for use as is. Vacuum suction and reciprocating distribution of the open tow web may be varied as desired to arrive at particular article thicknesses directed towards particular article uses.