Abstract: A fluid such as a fluidized bed or a molten bath, is heated to a temperature sufficiently high to soften a substantially rigid body of material and sufficiently low to avoid damage to the material. While maintaining the fluid at this temperature, the body is immersed in the fluid to heat the body uniformly. Pressure is applied to the heated body to form it into a desired three-dimensional configuration. The heated body is removed from the fluid either before, after, and/or while the pressure is applied. The body is allowed to cool and harden into its desired configuration. The body is preferably formed between a flexible member and a mold surface. The method may be used to form various types of material, including honeycomb core, laminated sheets of plastic, plastic tubing, and titanium. The body may be precut and indexed and secured to a mold which is immersed in the fluid with the body.

Abstract: An integrated three-component insulation wall assembly which can be used by itself as an insulation wall assembly, or which can be incorporated into a solid rocket motor case that is made of material fabricated using conventional layup construction methods, or which can provide the contour stability necessary to allow its functioning as a mandrel for filament-winding a solid rocket motor case, and which can be spliced and reinforced across the splice. The insulation wall assembly comprises, in an integrated condition, an inner wall component (i.e., a flame side wall component) which is laminated from woven reinforcements in an ablative matrix, a middle wall component of non-metallic honeycomb core material, and an outer wall (i.e., a pressure side wall component). The inner wall component provides a fire barrier; the middle wall component provides thermal insulation; and the outer wall component provides structural stability.