Moldable uncured nonwoven composite and molded cured composite

A process for forming a molded, cured composite comprising:

• forming a structural nonwoven layer having a first side, a second side, and an inner plane located at the mid-plane between the first and second side, wherein the structural nonwoven layer comprises a plurality of bi-component binder fibers and a plurality of reinforcing fibers, wherein the bi-component binder fibers and a plurality of reinforcing fibers, wherein the bi-component fibers comprise a core and a sheath, wherein the core comprises a polymer having a melting temperature of at least about 180° C. and the sheath comprises a polymer having a melting temperature less than about 180° C.;
• at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C. forming an uncured, wet nonwoven composite;
• at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130° C. forming an moldable, uncured composite;
• cutting the moldable, uncured nonwoven composite;
• applying heat and pressure to the moldable, uncured composite to a temperature of at least about 160° C. at least melting the sheath polymer of the binder fibers, bonding at least a portion of the reinforcing fibers to other reinforcing fibers, at least a portion of the reinforcing fibers to the cores of the bi-component binder fibers and at least a portion of the cores of the bi-component binder fibers to other cores of the bi-component binder together, and at least partially curing the thermosetting resin forming the molded, cured composite.