Patent ID: 7112299

Claim:
A method of fabricating a laminate article, comprising the steps of: providing a plurality of support templates; arranging the support template to define at least a portion of a part outline corresponding to the laminate article; providing a plurality of substantially flat, substantially rigid primary panels each defining an outer surface and an inner surface; securing the outer surfaces of the at least some of the plurality of primary panels to at least some of the plurality of templates such that the primary panels conform at least in part to the part outline; arranging at least one substantially flat secondary panel on the inner surfaces of the primary panels in a desired relationship with the primary panel; securing a vacuum bag to the at least one primary panel to define a vacuum chamber; and applying a vacuum to the vacuum chamber to remove air from between the at least one primary panel and the at least one secondary panel and thereby disperse hardenable material between the primary panel and the secondary panel; hardening the hardenable material such that the laminate article comprises the plurality of primary panels, the at least one secondary panel, and the hardenable material; detaching the plurality of templates from the at least one primary panel, where the outer surfaces of the plurality of primary panels form at least a portion of a finished surface of the laminate article.