Method of manufacturing a composite material

A method of manufacturing a structural member, the method comprising:

• moving a plurality of fibers (130) along an assembly line (100);
• applying a binder to at least one of the plurality of fibers (130), wherein when the binder is applied, the plurality of fibers (130) are spaced apart and extend across a first area;
• applying a traction agent (178) to at least one of the plurality of fibers (130) and the binder after applying the binder;
• providing a die (180) having a first portion (195) with a first diameter positioned to receive the plurality of fibers (130) and a second portion with a second diameter positioned downstream of the first portion (195), wherein the first diameter is greater than the second diameter and wherein the die (180) is tapered between the first portion (195) and the second portion;
• guiding the plurality of fibers along the die (180);
• decreasing a distance between adjacent fibers of the plurality of fibers (130) with the die (180), wherein after decreasing the distance between adjacent fibers of the plurality of fibers (130), the plurality of fibers (130) extend across a second area that is smaller than the first area;
• and
• after decreasing, shaping the plurality of fibers (130) with a shaping station (115),
• wherein the traction agent increases friction between at least one of the fibers (130) and either an adjacent fiber or the die during shaping.

A method of manufacturing a structural member, the method comprising:

• moving a plurality of fibers (130) along an assembly line (100) at a speed of greater than about 20 feet per minute;
• applying a binder to at least one of the plurality of fibers (130), wherein when the binder is applied, the plurality of fibers (130) are spaced apart and extend across a first area;
• applying a traction agent (178) to at least one of the plurality of fibers (130) and the binder;
• providing a die (180) having a first portion (195) with a first diameter positioned to receive the plurality of fibers (130) and a second portion with a second diameter positioned downstream of the first portion (195), wherein the first diameter is greater than the second diameter and wherein the die (180) is tapered between the first portion (195) and the second portion;
• guiding the plurality of fibers along the die (180);
• decreasing a distance between adjacent fibers of the plurality of fibers (130) with the die (180), wherein after decreasing the distance between adjacent fibers of the plurality of fibers (130), the plurality of fibers (130) extend across a second area that is smaller than the first area;
• and
• after decreasing, shaping the plurality of fibers (130) with a shaping station (115),
• wherein the traction agent increases friction between at least one of the fibers (130) and either an adjacent fiber or the die during shaping, and
• wherein the die (180) moves together with the plurality of fibers (130) along at least a portion of the assembly line (100).