Patent ID: 8177934

Claim:
A rotocast composite hybrid method, comprising: filling a mold with a volume of resin through an access port; sealing the access port by positioning a lid over the access port; mounting the mold in a rotocasting machine; operating the rotocasting machine to rotate the mold about two orthogonal axes, wherein a layer of the resin flows over an inner surface of the mold to form an outer wall of a part; removing the lid; and applying a reinforcement material to an inner surface of the outer wall of the part through the access port, wherein the resin is a two-part resin with a gel time and wherein the operating of the rotocasting machine to rotate the mold is performed for a time period exceeding the gel time and being less than a cure time or until the resin has gelled and the resin on the inner surface of the outer wall is soft and slightly tacky and wherein the applying of the reinforcement material comprises binding the reinforcement material to the inner surface by applying an additional volume of the resin to the reinforcement material, the additional volume of the resin and the volume of the resin provided in the filling step being cured without further rotating of the mold with the rotocasting machine.