Patent ID: 8263200

Claim:
A method of making a composite structure comprising a curved body and an integral rim extending from an end of the curved body, the method comprises the steps: forming a diaphragm pack comprising a flat stack of composite plies between two diaphragms wherein each ply of the flat stack is made up of a plurality of composite tiles, each tile having at least a first portion and a second portion, with side edges of the first portion being configured to abut against side edges of adjacent tiles and side edges of the second portion being configured to overlap side edges of adjacent tiles; placing the diaphragm pack in a double diaphragm forming apparatus comprising a hollow forming tool including evacuating air from within the diaphragm pack, wherein the first portion of the composite tiles is supported on an upper surface of the tool; applying heat to the diaphragm pack; and applying a vacuum between the lower diaphragm and the hollow forming tool such that: an unsupported region corresponding to the second portion of the composite tiles is drawn into contact with an internal wall of the forming tool; the edges of the second portion of adjacent tiles move to abut against side edges of adjacent tiles; the first portion of each tile forms part of the rim; and the second portion of each tile forms part of the curved body.