The development of innovative bio-based composites with high-efficient manufacturing processes is the purpose of the current project C4 in the framework of the Excellence Cluster MERGE EXC 1075, funded by DFG (Deutsche Forschungsgemeinschaft). A high-efficiency in terms of mass-production, reproducibility and flexibility requires the performance of successive steps in the manufacture of semi-finished and final bio-based products. About bio-based materials, natural fibers composite (NFC) prepregs have been recently investigated as a potential cost-efficient semi-finished product. By means of continuous production processes, prepregs rolls can be manufactured with unidirectional natural fibres (flax) fabrics as reinforcement and thermoplastic biopolymers films as matrix. The used natural fibre fabrics are made of high twisted yarns. For a better impregnation and higher stiffness properties, non-crimp fabrics with non- or low-twisted yarns, which have been lastly developed by natural fibres suppliers, represent an appropriate solution. A second suitable option is the substitution of the biopolymer films, whose impermeability does not facilitate the release of humidity from the natural fibres while the impregnation, by produced low cost thermoplastic spunlace non-woven fabrics with a higher permeability and lower reachable surface masses. The realization of these development steps can be followed up with a continuous NFC prepregs production process or with a high productive multi-axial warp knitting process, which can be adapted for an optimized placement of reinforcing yarns according to the possible load path of future products. These innovative technologies can be incorporated into new concepts and potential applications in several fields such as automotive industry or sport equipment. The mechanical properties profile of the combination of non-crimp natural fibers fabrics with thermoplastic non-woven spunlace fabrics has been here studied in detail with press-engineered samples and has confirmed their high application potential as an alternative to glass fiber-reinforced composite.