Method of forming nonwoven fabric with foamed fiber and manufacturing apparatus thereof

A method of forming a nonwoven fabric with foamed fiber and a manufacturing apparatus thereof are provided. The method includes providing a manufacturing apparatus including an extruder having a screw, a supercritical carbon dioxide supplying device, a static mixer, a spinning head, a carrier and an air extending device. The supercritical carbon dioxide supplying device is connected with the screw extruder. The static mixer is connected with an output of the extruder. The spinning head has at least one nozzle and is connected with the static mixer. The carrier is disposed under the spinning head. The air extending device has at least one air nozzle, and the nozzle of the spinning head and the air nozzle form a concentric structure. If a mother particle of the nonwoven fabric has a melt temperature Tm, the temperature of a first part of the screw is lower than Tm about 30 to 50 DEG C, the temperature of a second part of the screw is higher than Tm about 15 to 25 DEG C, and the temperature of a third part of th