Patent ID: 7820092

Claim:
A method of forming an elongated composite structural member, the method comprising: providing a substantially elongated mandrel having an exterior surface exhibiting desired geometry the elongated mandrel further exhibiting an arcuate portion along at least one section of a length thereof; laying up a first ply of preimpregnated fiber reinforced material over the mandrel; applying a force to the first ply to establish a desired amount of tension within the first ply, wherein applying a force to the first ply to establish a desired amount of tension within the first ply includes applying a force in a direction that is substantially tangent to a radius of curvature of the mandrel at a location where the first ply is being laid up on the mandrel; and pressing the first ply onto the mandrel in a conformal manner including passing at least one roller over the mandrel and the first ply while maintaining the desired amount of tension within the first ply, the at least one roller being at least partially complementary in shape with the mandrel.