Abstract: A net-shape ballistic panel is formed by a process of arranging a fiber bundle on a substrate to form a layer, the layer following a shape of the ballistic panel, securing the fiber bundle to the substrate with a plurality of stitches to form a preform layer, arranging additional layers of fiber bundles on the preform layer, each layer of the additional layers following the shape of the ballistic panel, and each fiber bundle being secured with a plurality of stitches to each layer of the additional layers to form a plurality of preform layers. A resin is then impregnated into the preform layers and subsequently cured using a process such as compression molding. The resulting ballistic panel is relatively thin while exhibiting an excellent ballistic rating (e.g., V50).

Abstract: A fiber preform for use in an overmolding process is provide that includes a fiber bundle arranged in a predetermined pattern and attached to itself with thread stitches to form at least one preform layer. At least one intumescent material is associated with the at least one preform layer. A vehicle component having fire resistant characteristics is also provided that includes a housing having a first side and a second side. The housing has a shape that defines the vehicle component. An intumescent material is provided on at least one of the first side and the second side of the housing.

Abstract: A fiber preform includes a substrate. A fiber bundle includes reinforcing fibers arranged on the substrate in a shape of a shoe sole and attached to the substrate by a plurality of stitches of the thermoplastic thread to form a first preform layer having a principal orientation. An orthotropic composite material shoe sole is also provided that includes the fiber preform with a cured molded resin surrounding the fiber preform, the cured molded resin having a shape of the shoe sole. A method of forming a fiber preform for use in a composite material shoe sole is also provided.