Apparatus and a method of preparing fiber preforms disperses fibers and
binder on a forming support surface such that the materials are
conditioned and then applied to the surface where the composite material
solidifies. Reinforcing material, such as fiber, is mixed with binder,
such as thermoplastic or thermoset materials, so that the materials
adhere. Then, the adhesive mixture is dispersed in a controlled
pre-determined weight ratio on the support surface where the mixture
sticks to the support surface, cools and solidifies. The deposited
mixture can be an open mat having interstices between fibers. The
deposited mixture can also be shaped further into a final desired shape
before complete solidification. This method eliminates the need for
solvents and their associated problems. The process does not require a
vacuum or plenum system to hold the reinforcing material in place. The
preform can be made in any shape, including sections or asymmetric
configurations and remain in mold while being processed to a composite
molded article.