Processes for mechanically fabricating two and three-dimensional fibrous monolith composites include preparing a fibrous monolith filament from a core composition of a first powder material and a boundary material of a second powder material. The filament includes a first portion of the core composition surrounded by a second portion of the boundary composition. One or more filaments are extruded through a mechanically-controlled deposition nozzle onto a working surface to create a fibrous monolith composite object. The objects may be formed directly from computer models and have complex geometries.
The present invention was made with U.S. Government support under grant Number DE-FC02-96CH10861, awarded by the Department of Energy, and under grant Number NAS8-00081 awarded by the National Aeronautics and Space Administration. Accordingly, the Government may have certain rights in the invention described herein.