Patent ID: 7754045

Claim:
A method of fabricating a composite beam having a J-shape cross section, comprising the steps of: (A) producing a C-channel by forming a first composite charge over a first tool; (B) moving a second flat composite charge into contact with the C-channel produced in step (A) to form a layup while said C-channel is supported over said first tool; (C) producing a first flange on one end of the beam by forming a first portion of the second flat composite charge over one end of the C-channel while said C-channel is supported over said first tool; (D) producing a second flange on the other end of the beam by forming a second portion of the second composite charge over a second tool while said beam is supported between said first and second tool; and, (E) curing the layup while said layup is supported between said first and second tools.