Abstract: A method for making a honeycomb core composite article includes forming a honeycomb core (24) and a precured composite skin (20) having a core edge (32) and a restraint edge (30), respectively. The precured composite skin (20) is placed in combination with a rigid mold member having a mold surface (12s) and the honeycomb core (24) is mated with the precured composite skin (20) to form a mated subassembly (36). An uncured composite skin (22) is laid over the mated subassembly (36) such that a peripheral portion (44) of the uncured composite skin (22) extends beyond the restraint edge (30) by a distance X and such that the peripheral portion (44) is in superposed abutting engagement with the mold surface (12s). The honeycomb core (24), the precured composite skin (20) and the uncured composite skin (22) define a composite lay-up (10) over which a vacuum bag (14) is disposed.

Abstract: A selectively-flexible, selectively-rigid, reusable, one-piece mold is used to fabricate a composite part having a complex shape on an outer surface of the mold. Disposed within the interior of the shell is a grid-type support truss structure having a plurality of individual support members attached at one end to headers that are attached by clips to the inside surface of the shell at predetermined locations. The support members are locked in place relative to each other by the use of pins placed in holes formed at various locations in the support members. When locked in place in this manner, the shell is stiffened, thereby facilitating the fabrication of the composite part on the mold. When the pins are removed, the shell is allowed to flex, thereby facilitating the removal of the cured composite part from the outer surface of the mold.