Patent ID: 7934307

Claim:
A method comprising: stocking a plurality of sheets of commercially available, off-the-shelf, expanded honeycomb material having a plurality of stock thicknesses, each sheet of material having a plurality of cells arranged in a planar array, the plurality of cells being defined by walls extending in planes substantially perpendicular to the planar array, the length of the walls defining the stock thickness; providing a support plate with a support plate thickness; providing a platen with a platen thickness, the platen having a plurality of teeth; selecting an axially height of a linear drive motor assembly; selecting a sheet of honeycomb material from the plurality based upon its stock thickness such that the honeycomb material sheet stock thickness together with the platen thickness and the support plate thickness correspond to the selected axially thickness; cutting the honeycomb material along its width and length to form a core; securing the platen directly to one side of the core in a direction parallel to the planar array; securing the support plate directly to the axially opposite side of the core; and providing a forcer having a motor stack magnetically coupleable to the platen to form the linear drive motor assembly.