Abstract: Apparatus and methods for multi-layer foam structures are disclosed. In one embodiment, a method includes filling a first portion of a receptacle with a removable filler. A second portion of the receptacle is filled with a first foam forming a first foam layer. The removeable filler is removed, and at least part of the first portion of the receptacle is filled with a second foam, forming a second foam layer. The first foam may include a polyimide foam, and the second foam may include a polyurethane foam. Other aspects of the invention include a skin attached to the receptacle and the first foam. In other embodiments, hexagonal honeycomb matrix may be used as a receptacle for the first foam and the second foam.

Abstract: Systems and methods for measuring a contour match between adjacent components are disclosed. In one embodiment, at least two pressure sensors are located between adjacent components. Each pressure sensor is adapted to obtain a pressure measurement at a location a predetermined distance away from the other pressure sensors, and to output a pressure measurement for each sensor location. An output device is adapted to receive the pressure measurements from at least two pressure sensors and display the pressure measurements. In one aspect, the pressure sensors include flexible thin film pressure sensors. In accordance with other aspects of the invention, a method is provided for measuring a contour match between two interfacing components including measuring at least one pressure applied to at least one sensor between the interfacing components.