Patent ID: 6918985

Claim:
A method for making a radome, comprising: placing a first dry fiber preform into a female mold having a mold surface contoured as a negative image of a desired contour to be imparted to an exterior surface of the radome; placing a foam core in the mold adjacent the first dry fiber preform, the foam core having first been thermally formed to generally match the contour of the mold surface prior to being placed in the mold, the foam core also being penetrated by a plurality of openings through the thickness of the foam core; placing a second dry fiber preform adjacent the foam core so as to form a sandwich structure having the foam core sandwiched between the dry fiber preforms; vacuum infusing the dry fiber preforms with a fluid heat-curable resin to impregnate the preforms with the resin; heating the sandwich structure to cure the resin; and extending fasteners through the openings defined by the foam core.