Commingled fiber preform architecture for high temperature composites

A manufacturing method, comprising:

• forming first fabric layers for a commingled fiber preform by arranging a first set of commingled fibers in a first direction with a second set of commingled fibers in a second direction, wherein the first set of commingled fibers comprises first fugitive fibers commingled with at least one of first carbon fibers or first fusible fibers commingled with first fugitive fibers and wherein the second set of commingled fibers comprises second carbon fibers;
• forming a second fabric layer for the commingled fiber preform by arranging a third set of commingled fibers in the first direction with a fourth set of commingled fibers in the second direction, wherein the third set of commingled fibers comprises third fugitive fibers commingled with at least one of third carbon fibers or third fusible fibers and wherein the fourth set of commingled fibers comprises fourth carbon fibers;
• and
• positioning the second fabric layer between the first fabric layers,
• wherein the first set of commingled fibers comprise a lower percentage of the at least one of first carbon fibers or first fusible fibers than the third set of commingled fibers,
• wherein the first set of commingled fibers comprise a higher percentage of first fugitive fibers than the third set of commingled fibers,
• wherein the first fugitive fibers and the third fugitive fibers are pyrolyzed from the first fabric layers and the second fabric layer to create a path through a thickness of the first fabric layers and the second fabric layer for infiltration of fluids,
• wherein the first fugitive fibers and the third fugitive fibers are comprised of a polymer with a combined char yield of 5% or less by weight, and a residual mass of less than 1% by weight, and
• wherein the first fusible fibers and the third fusible fibers are comprised of a polymer with a combined char yield of 25% or greater by weight and a residual mass of less than 1% by weight.