Patent ID: 7842145

Claim:
A method of forming a composite member, the method comprising: providing a contour surface corresponding in shape to a desired contour of the composite member for supporting a plurality of elongate tapes in a substantially parallel configuration, each tape including a plurality of reinforcement members disposed in a matrix material; and disposing each of the elongate tapes along a path defined by a plurality of natural path segments, each segment of a single path being disposed at a non-natural angle relative to adjacent segments of the path, and each tape comprising a plurality of physically discrete portions corresponding to the natural path segments and positioned relative to adjacent portions in a continuous, end-to-end manner in a lengthwise direction so as to define the non-natural angle between adjacent portions without discontinuities between consecutive portions, such that a transverse edge of each elongate tape is disposed within a predetermined offset distance interval from an adjacent one of the tapes.