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The development of binder systems for automotive sound insulators as an alternative to phenolic resin is presented. Various thermoplastic binder systems were evaluated. The non-woven airlay process technology was used in manufacturing the padding. Subsequent cold thermoforming techniques were employed to produce molded sound insulators. Material characterization and part performance evaluation of mechanical properties, heat resistance, and acoustical performance were determined. Manufacturing process for the molded sound insulator was also demonstrated. The study concluded that a thermoplastic binder system, as an alternate to phenolic binder resin, can be used to produce functional molded fiber floor insulators.