Abstract: A novel method is disclosed for fabricating a co-cured advanced composite integral one piece aerostructure article. The method comprises assembling on a composite bond jig a first uncured composite layer in the shape of at least one surface of a composite aerostructure article, the first composite layer having at least one uncured resin-impregnated laminate layer. At least one longitudinally extending hollow mandrel is secured on the upper surface of the first composite layer. A second uncured composite layer is assembled on the bond jig over the upper outer surface of the hollow mandrel and at least a portion of the first uncured composite layer, the second uncured composite layer having at least one uncured resin-impregnated layer. The lay up assembled on the composite bond jig is subjected to a cycle of predetermined pressure and temperature to cure such resin impregnated layers to form a unitary co-cured one-piece aerostructure article.

Abstract: An article is made by co-curing a lay up on a composite bond jig of fiber-reinforced composite materials having a lower layer, at least one elongated hollow mandrel of a stiffened graphite fabric having its lower surface adhered to the upper surface of the lower layer, and an upper layer adhered to the top and side surfaces of the hollow mandrel and at least portions of the upper surface of the bottom layer.