Patent ID: 7024897

Claim:
A method of forming a formable blank into a structural component having a predetermined shape, said method comprising: (a) providing a shape imparting shell formed from a rigid material, said shell being in the form of at least a first shell section and a second shell section, each of which includes an inner surface defining said predetermined shape, an outer support surface and spaced lateral edges which edges define a parting plane between said two shell sections when said two shell sections are brought together to at least partially form said shell; (b) providing a first compression force transmitting material with an upper side and a lower side to support said first shell section, said first compression force transmitting material having different physical properties than said first shell section; (c) providing a second compression force transmitting material with an upper side and a lower side to support said second shell section, said second compression force transmitting material having different physical properties than said second shell section; (d) placing said formable blank at least partially into said second shell section; (e) moving said shell sections together to at least partially capture said formable blank in said shape imparting shell; and, (f) at least partially heating at least a portion of said formable blank by at least one heating element until said formable blank at least partially conforms to at least a portion of the inner surfaces of said first and second shell sections to form said structural component.