Abstract: A dry fiber form, useful for the preparation of fiber/resin composites, is proposed by stitching a continuous tow of structural yarn to a substrate, according to a predetermined pattern. Numerous layers, similar or different to each other, are prepared, and adhered together. In one embodiment, the fibers are stitched to a removable substrate.

Abstract: A multiple-end weft-insertion process which is capable of achieving extremely high yarn density which is uniform in plys of structural fabrics is disclosed, making use of conventional machinery and systems. Yarn is transferred from a shuttle to yarn transfer elements spaced a sufficient distance apart to avoid damage to the yarn, and then transferred to yarn holding elements. Each successive pass of the shuttle is adjusted by moving the yarn transfer element parallel to the holding elements, so as to overlap each band deposited by the shuttle. The amount of movement necessary to achieve any desired density is calculated according to established parameters.

Abstract: A process for forming a dry fiber form susceptible of being infused with a resin and molded to a fiber reinforced plastic structural article, wherein the fiber form in comprised of a structural fabric bearing plys of biased yarns, the bias of the yarns being maintained along the curvature of the fiber form, without wrinkling or buckling of the fiber form. The structural fabric is attached to a form bearing a shape-defining opening, and threads are sewn within the opening. The fabric is then removed from the form, and the ends of the fabrics are then sewn with more threads parallel to the first set of threads. Thereafter, the excess is trimmed away, and the resulting sewn fiber form may be infused with resin and molded into a structural article.

Abstract: A structural fiber pre-form useful as a structural article when saturated with a resin which is subsequently cured is disclosed, which is comprised of a large number of tightly packed, parallel structural yarns. The yarns are held in alignment by a sewing yarn passing vertically around and between the yarns. The pre-form may be covered with a smooth covering, such as a fabric covering, which may either be sewn to the fiber pre-form in a single process, bound thereto by curing of a saturating resin, or a combination of processes.