Patent ID: 8449707

Claim:
A method of manufacturing a multi-layer composite structure having a width, length, and height, the method comprising: heating a sheet of fiber-infused thermoplastic polymer; forming said heated sheet of fiber-infused thermoplastic polymer into a structural core having a pyramidal geometric pattern, wherein said pyramidal geometric pattern repeats along a length and a width of said structural core, is symmetric about a neutral axis of said structural core, and is comprised of a plurality of pyramidal shapes, and wherein each of said pyramidal shapes has at least four side-faces intersecting at respective edges, each of said edges including a radius; thermally bonding a first thermoformable reinforcement layer to a top of said structural core, said first reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core; and thermally bonding a second thermoformable reinforcement layer to a bottom of said structural core, said second reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core.