Abstract: A method for producing composite, structural plastic parts in traditional foundry molds, including sand, permanent, die-cast, wax and investment molds. Short fiber length fibers reinforcing low viscosity thermoset resins, and in particular resole phenolics, provides a pourable low bulk density polymer compound with minimal externally applied thermal requirements during molding and post cure when required. Foundries can consider metal parts replacement with this new method. It permits foundries to actually produce composite, structural plastic parts with superior mechanical and thermal properties. This permits them to provide plastic products on a competitive basis with the compression and injection molders.

Abstract: A cylinder head and engine block assembly for internal combustion engine includes a cylinder head formed from a fiber-reinforced phenolic resin, and an engine block formed from a fiber-reinforced phenolic resin, and an arrangement for placing the head and block assembly under a loading compression pressure; preferably the fiber reinforcement is made up of fibers of fiberglass or graphite having a length of about 1/8" to 1"; the cylinder head body has embedded in or united with it a unitary metal insert defining the upper portion of at least one inlet port and at least one exhaust port and combustion chamber, the block has embedded in or united with it a unitary metal unit defining at least one cylinder liner, and the block has upper bearing supports embedded in or united with the block.