Patent ID: 8302842

Claim:
A method of creating a honeycomb core, the method comprising the steps of: a) placing a first sheet on top of a second sheet to create a stack; b) welding the first sheet to the second sheet using a first serpentine welding pattern that includes welding a long weld followed by welding a generally orthogonal short weld in a repeated parallel sequence; c) welding a third sheet to the top of the stack using a second serpentine welding pattern that includes welding a long weld followed by welding a generally orthogonal short weld in a repeated parallel sequence, such that the long welds of the second serpentine welding pattern are shifted from the long welds of the first serpentine welding pattern; and d) trimming opposing sides of the stack to remove the short welds of the first serpentine welding pattern and the second serpentine welding pattern.