An all-silk composite, in which uniaxially-aligned and continuous-typed Bombyx mori silk fibers were embedded in a matrix of silk protein (fibroin), was successfully prepared via a solution casting process. The structure, morphology, mechanical and thermal properties of such silk fiber/fibroin composites were investigated with X-ray diffraction, scanning electron microscopy, tensile and compression tests, dynamic mechanical analysis and thermogravimetric analysis. The results demonstrated that the interface adhesion between silk fiber and the fibroin matrix was enhanced by controlling the fiber dissolution through 6 mol L-1 LiBr aqueous solution. Compare to those of the pure fibroin counterparts, the overall mechanical properties as well as the thermal stability of such silk fiber/fibroin composites were significantly improved. For example, the composite with 25 wt% fibers showed a breaking stress of 151 MPa and a breaking elongation of 27.1% in the direction parallel to the fiber array, and a compression modulus of 1.1 GPa in the perpendicular direction. The pure fibroin matrix (film), on the other hand, typically had a breaking stress of 60 MPa, a breaking elongation of 2.1% and a compression modulus of 0.5 GPa, respectively. This work suggests that such a controllable technique may help in the preparation of animal silk based materials with promising properties for various applications. (C) 2010 Elsevier Ltd. All rights reserved.