Patent ID: 8865044

Claim:
A method of fabricating a formed structure with a stitched foam core comprising: forming a foam core, the core comprising a first core face, a second core face, a top core edge and a bottom core edge; wrapping the foam core with a first layer of fiber tape, the first layer of fiber tape extending continuously along the first core face, top core edge, second core face and bottom core edge of the foam core, wherein the wrapped core has a first wrapped face, a second wrapped face, a top wrapped edge and a bottom wrapped edge; placing at least two separate pieces of non-tacky veil material on the wrapped core; stitching the foam core with a thread, the thread extending along the core; wrapping a portion of the core with a second layer of fiber tape to form a preform; placing the preform in a mold; heating the mold; cooling the mold; and removing the formed structure from the mold.