Abstract: A method of forming a three-dimensional composite structure. Uncured portions of the composite structure are first assembled between a initially rigid heat-softening inner layer of ABS plastic and a hard outer mold surface. Prior to curing of the composite structure, pressure and heat is applied to the ABS layer to soften the layer. Thereafter, pressure is applied to the side of the ABS layer opposite from the composite structure, thereby to compact the uncured portions of the composite structure against the hard outer mold. Stiffening beams may be incorporated into the composite structure, so as to yield a lightweight, strong composite structure that can be used as a pressure vessel in an aerospace vehicle.

Abstract: A method and a device for introducing reinforcing strands into a vertical mold through the open upper end thereof. An array of strand material is positioned to extend across the open end of a mold and an insertion device is lowered into the mold. The insertion device engages the strand material during its downward motion and draws an appropriate amount of such material from a continuous supply thereof to give a strand reinforcement of elongate U-shape within the mold. A reciprocable carriage is provided whereby the leading end of the strand is presented to a clamp at a remote side of the mold opening, the carriage having a selectively operable clamp thereon for engagement with the strand during movement of the carriage toward the clamp.