Method of manufacturing cross-corrugated support structures

A method of manufacturing a cross-corrugated support structure, said method comprising the steps of:

• providing a mold having a molding surface,
• the molding surface being a continuous surface having a first plurality of mold corrugations and a second plurality of mold corrugations,
• the first plurality of mold corrugations being defined by a series of alternating primary ridges and primary grooves extending a length of the molding surface in a first direction,
• wherein each primary ridge and primary groove has a mold face extending therebetween,
• the second plurality of mold corrugations being defined by a series of secondary ridges and secondary grooves extending a length of the molding surface in a second direction perpendicular to and intersecting with the first direction such that each mold corrugation within the second plurality of mold corrugations intersects the mold face extending between each primary ridge and primary groove, wherein each secondary ridge and secondary groove is disposed on a surface of the mold face extending between each primary ridge and primary groove;
• placing a flexible carbonaceous sheet onto the molding surface;
• encapsulating the sheet with a bag to form a vacuum chamber,
• wherein the sheet is disposed between the molding surface and the bag when encapsulated;
• infusing the sheet with thermosetting resin;
• evacuating the vacuum chamber of air contained therein, thereby drawing the sheet upon the molding surface such that the sheet forms a shape having a first plurality of sheet corrugations, a second plurality of sheet corrugations, and sheet faces,
• wherein the first plurality of sheet corrugations, the second plurality of sheet corrugations, and the sheet faces within the sheet match the first plurality of mold corrugations, the second plurality of mold corrugations, and the mold faces of the molding surface;
• curing the resin such that the sheet rigidly retains the shape formed when evacuating the vacuum chamber;
• and
• securing a support member to the sheet transverse to the first plurality of sheet corrugations.