The present invention relates to a manufacturing method of applying dry powder in a controlled manner to a variety of surfaces to form shapes, coatings, or composite materials. This is achieved by coating the surface with a tacky substance, applying the powder, and then coating the powder with a barrier coating that is insoluble in the solvent used in the tacky layer. The process is repeated to add the desired amount of powder. By the selection of powder size, size distribution, shape, and number of layers, precise control of mass loading can be achieved. The method can be used with titanium powder to form powder-coated fiber, non-woven mat, and tape cast performs which can be processed into fiber reinforced composite materials.