Abstract: A system and method for making and using composite material components is disclosed. Composite material components are preferably constructed in patterns where every part needed for a given filler is included in a single series pattern. Using these series patterns, the material can be cut, folded and the parts created in a manner such that the individual parts forming a single filler are releasably attached to one another, thus resulting in effective and efficient organization of these parts. The filler panels can then be arranged into a folding stack of offset edges. Two shapes are preferably used with subtle differences between each at the fold area. Different patterns can be used to have the first two panels in the series positioned at 0 degrees, followed by two panels positioned at 45 degrees, and then alternating the angle positions throughout the pattern. The pattern preferably incorporates triangular portions or tabs between each set of panels in the series to help in establishing a fold line.

Abstract: A system and method for making and using composite material components is disclosed. Composite material components are preferably constructed in patterns where every part needed for a given filler is included in a single series pattern. Using these series patterns, the material can be cut, folded and the parts created in a manner such that the individual parts forming a single filler are releasably attached to one another, thus resulting in effective and efficient organization of these parts. The filler panels can then be arranged into a folding stack of offset edges. Two shapes are preferably used with subtle differences between each at the fold area. Different patterns can be used to have the first two panels in the series positioned at 0 degrees, followed by two panels positioned at 45 degrees, and then alternating the angle positions throughout the pattern. The pattern preferably incorporates triangular portions or tabs between each set of panels in the series to help in establishing a fold line.