Patent ID: 8128775

Claim:
A process of producing a composite structure comprising a resin-infused fabric stack, the process comprising: placing at least one mat member, at least one non-impregnated fabric member, and at least one resin film on a tool surface so that pins disposed on the mat member project through the non-impregnated fabric member and the resin film to define holes therein, the non-impregnated fabric member being between the mat member and the resin film, the non-impregnated fabric member and the resin film comprising a stack that conforms to the mat member and the tool surface; placing a caul member on the stack to apply pressure thereto, the caul member having apertures therein that are penetrated by the pins of the mat member as a result of the caul member being placed on the stack; heating the stack to melt the resin film and cause molten resin thereof to flow around the pins of the mat member and infuse the non-impregnated fabric member and yield a resin-infused fabric stack; at least partially curing the molten resin within the resin-infused fabric stack; and then removing the at least partially-cured resin-infused fabric stack from the tool surface and from the mat member, wherein the partially-cured resin-infused fabric stack comprises holes that have resin-rich walls molded in-situ around the pins of the mat member and comprise the holes previously defined in the non-impregnated fabric member.