Patent ID: 8017054

Claim:
A method of fabricating a composite article comprising the steps of: providing a plurality of support templates; arranging the support templates to define a shape of the composite article; providing a plurality of primary panels, where each primary panel defines at least one edge, a first surface, and a second surface, and at least one of the primary panels is a flat primary panel the first and second surfaces of which are substantially planar and substantially parallel; providing a plurality of secondary panels, where each secondary panel defines at least one edge, a first surface, and a second surface; providing a plurality of tertiary panels, where each tertiary panel defines at least one edge, a first surface, and a second surface; bending the at least one flat primary panel such that the first and second surfaces thereof are no longer substantially planar; securing the first surface of the plurality of primary panels to the plurality of templates such that at least one edge of one of each the primary panels is adjacent to at least one edge of another of the primary panels, and the primary panels conform to the shape of the composite article; forming an inner skin by joining the adjacent edge portions of adjacent primary panels; after the inner skin has been formed, arranging the plurality of secondary panels such that the first surfaces of at least some of the secondary panels are adjacent to the second surfaces of at least some of the primary panels, and at least one edge of each of the secondary panels is adjacent to at least one edge of another of the secondary panels; joining the second surfaces of at least some of the primary panels to the first surfaces of at least some of the secondary panels adjacent thereto; forming a core by joining the adjacent edge portions of the secondary panels; after the core has been formed, arranging the plurality of tertiary panels such that the first surfaces of at least some of the tertiary panels are adjacent to the second surfaces of at least some of the secondary panels, and at least one edge of each of the tertiary panels is adjacent to at least one edge of another of the tertiary panels; joining the second surfaces of at least some of the secondary panels to the first surfaces of the tertiary panels adjacent thereto; forming an outer skin having exposed edge junctures by joining the adjacent edge portions of the tertiary panels; finishing the outer skin of the composite article by finishing the exposed edge junctures of the tertiary panels; and removing the plurality of support templates from the plurality of panels.