Patent ID: 8034263

Claim:
A method of manufacturing a multi-layer panel having a curved reflective and/or transmitting facing layer, the method comprising the steps of: clamping a thin membrane between an inner circular frame and outer circular frame the inner circular frame and the outer circular frame forming a frame; placing the frame and the thin membrane on top of a pressure chamber; temporarily sealing the frame and the thin membrane to the pressure chamber so that an airtight seal is formed between the frame and the pressure chamber; blowing air into the pressure chamber and, under pressure or pressure differential, blowing the thin membrane up to form a required shape; applying a first layer of material to an outer surface of the thin membrane while the thin membrane is maintained in the required shape; allowing the first layer of material to cure for a first predetermined time; applying a second layer of material to the first layer of material while the thin membrane is maintained in the required shape; and allowing the second layer of material to cure for a second predetermined time, the second layer of material reinforcing the first layer of material.