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The use of biomass fiber reinforcement for polymer composite applications, like those in buildings or automotive, has expanded rapidly due to the low cost, high stiffness, and inherent renewability of these materials. Biomass are commonly disposed of as waste.

This invention introduces a continuous composite forming process that produces large parts with variable cross-sections and shapes, exceeding the size of the forming machine itself.

Fiberglass, semi-structural insulation for recycled glass fiber and using a low cost silicon with pultruded rods, either fiberglass and a low cost resin, polyester for pultruded rods. It will reduce the use of wood, which is flammable, and still be structural.

Through the use of splicing methods, joining two different fiber types in the tow stage of the process enables great benefits to the strength of the material change.

Wire arc additive manufacturing has limited productivity and casting processes require complex molds that are expensive and time-consuming to produce.

ORNL has developed a new hybrid additive manufacturing technique to create complex three-dimensional shapes like air foils and wind generator blades much more quickly.

Important of the application is enabling a cost-effective precision manufacturing method Current technology is limited to injection molded individual pi-joints limiting control of pi-joint direction, this creates hurdle in introducing high volume production to the composite in