Patent ID: 7210611

Claim:
A method of forming a structural assembly having a predetermined configuration, the method comprising: forming first and second joints between a skin member and a support member and thereby joining the skin member and the support member to form a preform with a configuration corresponding to the predetermined configuration of the structural assembly such that the preform defines a space between the skin and support members and between the first and second joints, the joints extending annularly with the second joint disposed radially within the first joint such that the space extends annularly, and at least one aperture through the support member being in fluid communication with the space; and providing a pressurized fluid through the at least one aperture in the support member and thereby superplastically forming the skin member to a contour of the structural assembly with the support member extending in a substantially direct configuration between opposing portions of the skin member such that the skin member defines an inlet of an engine nacelle and the support member defines a bulkhead within the inlet.