Abstract: A structure includes a skin and a foam member. The foam member has a molded contour, the mold contour being configured to provide tooled surface for the skin. When the skin is a composite skin, the foam member provides support for the skin so that the skin can be cured under heat and pressure. A method of making the foam member for a foam stiffened structure includes creating a mold having an interior cavity which resembles a desired shape the foam member. A subsequent step involves introducing a foam mixture into the mold. Next, the foam mixture is allowed to polymerize so as to expand and distribute within the cavity of the mold. The method further includes selectively controlling a density of the foam member in the mold. The foam member is at least partially cured. The foam member is assembled with a skin to produce the foam stiffened structure.

Abstract: A composite structure includes a first face sheet, a second face sheet, and a foam member located between the first face sheet and the second face sheet. The foam member has a molded contour, the mold contour being configured to provide tooling surface for at least one of the first face sheet and the second face sheet prior to curing of the composite structure. A method of making the foam member includes creating a mold tool having an interior surface which resembles the desired outer contour of the foam member. A mixture is poured into a pour opening in the mold tool. The mixture is allowed to polymerize into a foam as the foam expands and distributes within the mold tool. Vent openings in the mold tool are selectively tailored to control the density of the foam member. The foam member is cured in the mold tool.

Abstract: A composite structure includes a first face sheet, a second face sheet, and a foam member located between the first face sheet and the second face sheet. The foam member has a molded contour, the mold contour being configured to provide tooling surface for at least one of the first face sheet and the second face sheet prior to curing of the composite structure. A method of making the foam member includes creating a mold tool having an interior surface which resembles the desired outer contour of the foam member. A mixture is poured into a pour opening in the mold tool. The mixture is allowed to polymerize into a foam as the foam expands and distributes within the mold tool. Vent openings in the mold tool are selectively tailored to control the density of the foam member. The foam member is cured in the mold tool.

Abstract: A structure includes a skin and a foam member. The foam member has a molded contour, the mold contour being configured to provide tooled surface for the skin. When the skin is a composite skin, the foam member provides support for the skin so that the skin can be cured under heat and pressure. A method of making the foam member for a foam stiffened structure includes creating a mold having an interior cavity which resembles a desired shape the foam member. A subsequent step involves introducing a foam mixture into the mold. Next, the foam mixture is allowed to polymerize so as to expand and distribute within the cavity of the mold. The method further includes selectively controlling a density of the foam member in the mold. The foam member is at least partially cured. The foam member is assembled with a skin to produce the foam stiffened structure.

Abstract: A composite structure includes a first face sheet, a second face sheet, and a foam member located between the first face sheet and the second face sheet. The foam member has a molded contour, the mold contour being configured to provide tooling surface for at least one of the first face sheet and the second face sheet prior to curing of the composite structure. A method of making the foam member includes creating a mold tool having an interior surface which resembles the desired outer contour of the foam member. A mixture is poured into a pour opening in the mold tool. The mixture is allowed to polymerize into a foam as the foam expands and distributes within the mold tool. Vent openings in the mold tool are selectively tailored to control the density of the foam member. The foam member is cured in the mold tool.

Abstract: A structure includes a skin and a foam member. The foam member has a molded contour, the mold contour being configured to provide tooled surface for the skin. When the skin is a composite skin, the foam member provides support for the skin so that the skin can be cured under heat and pressure. A method of making the foam member for a foam stiffened structure includes creating a mold having an interior cavity which resembles a desired shape the foam member. A subsequent step involves introducing a foam mixture into the mold. Next, the foam mixture is allowed to polymerize so as to expand and distribute within the cavity of the mold. The method further includes selectively controlling a density of the foam member in the mold. The foam member is at least partially cured. The foam member is assembled with a skin to produce the foam stiffened structure.