Method of manufacturing a friction article

A method of manufacturing a friction article for use in a brake comprising the steps of:

• stamping a blank having a predetermined shape from a web of open foamed material selected from a group consisting of carbon, iron, silicon carbide, nickel, and aluminum, said web having voids therein produced by a substantially continuous three dimensional matrix, said three dimensional matrix providing uniform structural rigidity for said blank and a conductive flow path for thermal energy;
• placing said blank on a conveyor;
• preparing a slurry made up of fillers, modifiers and a liquid binder in a volatile solution;
• moving said blank to a location where said slurry fills said voids to create a preformed friction article;
• transporting said preformed friction article to a dryer where about fifty percent of said volatile solution is removed without the formation of surface depressions caused by the release of bubbles of gas;
• conveying said dried preformed friction article to an oven to cure said binder and form a second matrix which holds said fillers, modifiers, and fibers in said three dimensional matrix;
• and
• applying a force to said preformed friction article during curing to produce a desired density in said friction article.