Would be interesting to find a fiber that is stiffer than nylon etc. Would be OK if it was a slightly brittle (like glass fiber).
Gel spinning sounds interesting... Would be OK if the stuff took a while to set and cure after initial deposition.
Synthetic silk spinning
An excellent general reference on fiber spinning is:
A. Ziabicki, Fundamentals of Fiber Formation, Wiley, New York (1976). ISBN 0471982202.
A classic article which emphasizes structure development during melt spinning is:
J.R. Dees and J.E. Spruiell, J. Appl. Polym. Sci., 18, pp. 1053-1078 (1974).
Epoxy bonded joints - how strong are they?