Low density cloth preform and methods of manufacturing same

A method for manufacturing a low density cloth preform, the method comprising the steps of:

• receiving cloth preform material atop a foam base that is resilient and has a density and thickness, wherein the cloth preform material has a top surface;
• rotating the cloth preform material at a rotational speed along an arcuate path about a vertical axis;
• needling the cloth preform material with a plurality of barbed needles depending from a needling board while the cloth preform is present beneath the needling board, wherein prior to needling the top surface has a first elevation and during needling the top surface is deflected downward to an elevation lower than the first elevation;
• and
• after needling, determining a second elevation of the top surface of the cloth preform material at a location along the arcuate path that is distant from the plurality of barbed needles by an arc length;
• wherein the foam density, foam base thickness, rotational speed, and arc length are selected to cause the top surface of the cloth preform material to rebound in an upward direction after needling such that the second elevation substantially equals the first elevation by the time the cloth preform material rotates through the arc length.