Abstract: A form for a vehicle component including a commingled fiber bundle laid out in a two-dimensional base layer that defines a shape of the form, a successive layer formed with the commingled fiber bundle in contact with the two-dimensional layer, and at least one of electrical conductive wiring, sensor, light emitting diode (LED), antenna, radio frequency identification chip, or a printed circuit board stitched to the successive layer. The comingled fiber bundle is composed of a reinforcement fiber being glass fibers, aramid fibers, carbon fibers, or a combination thereof.

Abstract: A method of manufacturing comingled yarn of carbon and thermofusible fibres comprises the steps of: feeding a tow of thermofusible fibres from a spool to a blending roller and between the spool and the blending roller, spreading the thermofusible tow; feeding a tow of carbon fibres from a spool to the blending roller; spreading the carbon fibre tow between the spool and the blending roller by applying a flow of air over the tow to urge the tow against a supporting surface over which the carbon fibres pass on their way to the blending roller; combining the thermofusible and carbon fibre tows at the blending roller.

Abstract: A method of manufacturing comingled yarn of carbon and thermofusible fibres comprises the steps of: feeding a tow of thermofusible fibres from a spool to a blending roller and between the spool and the blending roller, spreading the thermofusible tow; feeding a tow of carbon fibres from a spool to the blending roller; spreading the carbon fibre tow between the spool and the blending roller by applying a flow of air over the tow to urge the tow against a supporting surface over which the carbon fibres pass on their way to the blending roller; combining the thermofusible and carbon fibre tows at the blending roller.