Patent ID: 8101035

Claim:
A method of making a mandrel that is used as a substrate in the manufacture of a woven or braided article, comprising the steps of: providing a mandrel core of foam having two ends and one or more sides, overlaying the foam core with a sleeve of carbon fibers in contacting engagement with the foam core and enveloping each of the one or more sides of the foam core, the carbon fibers axially-aligned relative to a longitudinal axis of the mandrel body, the sleeve comprising resilient fibers transverse to the carbon fibers; applying a resin to the carbon fibers to create a carbon fiber-reinforced resin layer; after the carbon fiber-reinforced resin layer cures, overlaying the carbon fiber-reinforced resin layer with a sleeve of glass fibers; applying a resin to the glass fibers to create a glass fiber-reinforced resin layer forming a dimensionally-stable composite mandrel.