Abstract: A process for continuous production of z-threaded fiber reinforced polymer composites. The process includes providing a pre-formed fiber fabric including a plurality of fibers and a pre-formed, solidified film having a film thickness dimension, wherein the film includes a heat-meltable base matrix material in combination with a plurality of z-aligned nanofibers disposed within the base matrix material. The film and fiber fabric are advanced in layered relation through a constricting matrix transfer station, wherein the fiber fabric is heated to a temperature at or above the melting point of the base matrix material and the base matrix material progressively melts at an interface with the fabric face and flows with the nanofibers into the fiber fabric in the fabric thickness dimension as the film and fiber fabric move through the matrix transfer station.