The novel development of a photofabrication process of biofiber composites, based on oil palm empty fruit bunch fibers, is reported. The process consists of the following steps: (1) the preparation by a wet process of nonwoven mat of biofiber, either alone or in combination with glass and nylon; (2) drying the mat; (3) preparation of photocurable resin matrix, consisting of vinyl ester and photoinitiator; (4) impregnation of the mat by photocurable resin; and (5) irradiation of the impregnated mat by UV radiation to effect the cure of the composite. The nonwoven mat was formed in a "headbox" into which was poured a slurry of fibers. A wet mat was formed by after dewatering of the slurry. Biofiber, glass, and nylon fibers were mixed in different proportions. A "mixture experimental design" was used to generate experimental compositions of the reinforcing fibers and to model dependency of the response variables on the components through mathematical relationships. These relationships were meant to (1) determine the effect of composition of the reinforcing fibers on the physical and mechanical properties, (2) predict the response for any unknown composition of fibers, and (3) determine the optimum values of any identified properties. Because the product was characterized by multiple responses, simultaneous maximization of all properties was not feasible. The product must be considered in the definition of the trade-off or compromise of properties to obtain overall satisfactory performance. Such an optimization was carried out and the results are reported. (C) 2005 Wiley Periodicals, Inc.