Patent ID: 7311866

Claim:
A method of producing a three-dimensional composite support structure for supporting a body comprising the steps of: a) providing a three-dimensional model of the body; b) coupling a flexible pattern to a portion of the model; c) covering the body model and flexible pattern with a deformable thermoplastic polymer layer; d) applying one of pressure or vacuum to the thermoplastic polymer layer so as to cause an imprint of the flexible pattern to be formed into the polymer layer; e) allowing the thermoplastic polymer layer to harden into a splash mold; f) removing the splash mold from the body model and flexible pattern; g) removing the flexible pattern from the model; h) applying reinforced polymer into the imprint of the flexible pattern in the splash mold; i) coupling the splash mold containing the reinforced polymer to the model of the body; and j) applying at least one of pressure or vacuum to the model and the splash mold in the presence of heat so as to form the reinforced polymer material.