Methods and apparatus including a fiber opening chamber having an open upper end and a lower end, at least one fiber inlet for introducing a multiplicity of fibers into the opening chamber, a first multiplicity of rollers positioned within the opening chamber wherein each roller has a multiplicity of projections extending outwardly from a circumferential surface surrounding a center axis of rotation, at least one gas emission nozzle positioned substantially below the first multiplicity of rollers to direct a gas stream generally towards the open upper end of the opening chamber, and a forming chamber having an upper end and a lower end, wherein the upper end of the forming chamber is in flow communication with the open upper end of the opening chamber, and the lower end of the forming chamber is substantially open and positioned above a collector having a collector surface.