A method and apparatus for combining raw fibrous and binding materials in
a single mixing step (Step S3), followed by consolidation (Step S5) so as
to greatly shorten the overall cycle time to a finished fiber-reinforced
composite part. Chopped fibrous materials and binder materials are
deposited sequentially onto a belt conveyor (Step S2) so that the
materials are successively layered, one on top of each other in a
predetermined ratio, and subsequently mixed (Step S3) to achieve uniform
dispersion throughout. The mixed materials are then deposited into a
rotating mold (Step S4) to further ensure uniform dispersion of fibrous
and binder materials. Impregnation of the fibrous materials with the
binder material occur in-situ as the uniformly mixed materials are heated
and subsequently compacted in the mold (Step S5) to obtain the desired
shape of the fiber-reinforced composite part.