Patent ID: 8007705

Claim:
Process of manufacturing a one-piece composite part, comprising the steps of: (a) forming a shape memory polymer (SMP) without a memorized shape into the shape of a form with a hollow core for a one-piece composite part and solidifying the SMP form, said form having a shape that does not draw from the composite part, said form provided with a rigid insert designed to draw from its hollow core; (b) with the SMP form in its glassy state, laying up a composite material on the polymer form; (c) solidifying the composite material to form a one-piece composite part; (d) heating the SMP form to transition from its glassy state to its elastomeric state without relaxing to a memorized shape and changing the shape of the SMP form; (e) drawing the rigid insert out of the polymer form; and (f) drawing the form in its elastomeric state from the one-piece composite part thereby deforming the form as it is removed, said form returning to its original shape for the one-piece composite part upon removal.