A novel system that forms two-dimensional (2D) structures on a rotating drum and three-dimensional (3D) structures on 3D molds through proper integration of a laboratory scale meltblown unit with a small die and six-axis robot is briefly described. The system advantages over traditional systems are demonstrated. Parametric studies evaluating the effect of take-up speed, die-to-collector-distance (DCD), polymer throughput rate, and attenuating air pressure on the fiber orientation distribution functions (ODFs) of 2D structures formed by the system are reported. An additional new parameter termed “fiber-stream approach-angle” is introduced and its impact on the ODF of 2D structures is also reported. Under the experimental range studied, the ODFs were significantly impacted by the parameters studied. The fiber-stream approach angle showed the highest impact, among the parameter studied, on the ODF.
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