Although Japan has been using microdenier fibers in dry laid needlepunched nonwovens for some time, the United States has just begun to use microfibers in the dry laid process. The opening, blending, and carding of microfibers, specifically the carding rates, wire considerations, and recommended reconfigurations, are discussed. The most critical problem with carding microfibers is the formation of neps, which usually stems from the fiber type, speed ratios, amount of fiber recycling, edge suction, and prevention burbulence. The web weight and staple length are critical factors during crosslapping, as is the tension between the doffer of the card and the feed-in apron of the crosslapper. End-product application will dictate the needle loom configuration, such as needle densities and direction of the stroke. The control of the batt entering the needle zone is also critical. Needle selection, typically in the 40-42 gage, with preneedling using 40 gage RB needles, is recommended.