Patent ID: 8579181

Claim:
A method of forming an internal structure in a hollow component, the method comprising the steps of: forming an assembly having first, second, and third plates, the first and second plates each with a substantially planar surface and a surface with at least one protrusion, the surfaces including said at least one protrusion being on the exterior facing surfaces of the assembly, and the third plate being sandwiched between the first and second plates and having multiple slots opening through the third plate to divide the third plate into multiple separate plate portions; selectively bonding each plate portion of the third plate to a section of the first or second plates at a bond location substantially opposite one of the at least one protrusions of the first and second plates, wherein the width of each plate portion, extending in a direction from one adjoining plate portion to another adjoining plate portion, is greater than the width of the corresponding bond location in the same direction; and forming the assembly against a die such that the at least one protrusions of the first and second plates are transferred from the exterior facing surfaces to the interior facing surfaces of the first and second plates.