A chopped strand mat formed of bundles of dielectrically dried reinforcing
fibers and bonding fibers is provided. The reinforcing fibers may be
formed as bundles of wet reinforcing fibers with a bundle tex of about 10
to about 500. The reinforcing fibers may be formed of a single chop
length of about 1 to about 11/2 inches or a multi-chop length of fibers
of about 1/2 to about 2 inches. The bonding materials may be any
thermoplastic or thermosetting material having a melting point less than
the reinforcing fiber. The chopped strand mat may be formed by
dielectrically drying the wet reinforcement fibers, blending the
reinforcement and bonding fibers, bonding the reinforcement and bonding
fibers to form a chopped strand mat, compacting the mat, cooling the mat,
and winding the mat into a continuous roll. The chopped strand mat
contains a uniform or nearly uniform distribution of bonding fibers and
bundles of dried reinforcement fibers.