Carbon particles, such as, carbon fibrils and carbon nanotube molecules,
may be assembled into substantially pure aligned fibers by a) dispersing
the carbon particles within a curable liquid, b) aligning the carbon
particles by flowing the mixture of curable liquid and carbon particles
down a tapering tube, and c) curing the flowing mixture of curable liquid
and carbon particles in the general vicinity of the end of the tapering
tube to form a fiber. The curable liquid may be cured using ultraviolet
light. The solidified mixture may be further processed by d) heating the
fiber so as to cause the volatile elements of the solidified curable
liquid portion to substantially dissipate from the fiber, e) twisting the
fiber to increase its density, f) heating the fiber to sinter the carbon
particles within the fiber, and g) cladding the fiber. The resulting
fiber may then be spooled onto a take-up drum.