Abstract: A method and apparatus for forming a layer structure, such as an airlaid fibrous web, include a supplying mechanism for providing a stream of particulate material, such as fibers. Also included is a substantially endless, foraminous forming belt which has an appointed outward surface and a minimum thickness of at least about 3/16 inch. A selected contour is formed into the outward surface of the belt at selected locations, and the contour is distributed along a lengthwise machine-direction of the forming belt. The forming belt is configured to flex along a thickness direction thereof, and to recoverably bend and substantially straighten when traveling along a selected belt path circuit. A conveying mechanism moves the forming belt past the supplying mechanism along a forming path section of the belt circuit which is substantially straight, and moves the forming belt along a return path section of the belt circuit which includes curved portions therein.