Grid structures having glueless sleeve joints and methods of manufacturing and using the same

A metallic grid structure for use in a composite laminate structure, the grid structure comprising:

• a seamless metallic grid having a plurality of intersecting ribs oriented in at least two distinct rib directions offset at a variable angle relative to one another and defining respective intersection points,
• wherein:
• the variable angle is present in two or more distinct values lying in a range between 25 and 60 degrees;
• the intersection points define glueless joints of the metallic grid;
• and
• the metallic grid is a non-aluminum-based material.

A method of manufacturing a glueless grid and skin assembly for use in a composite laminate structure, the method comprising the steps of:

• providing a non-aluminum-based and planar component having a desired surface area and thickness;
• cutting the non-aluminum-based and planar component to define a metallic grid with a pattern defined by a plurality of intersecting ribs oriented in at least two distinct rib directions offset at a first variable angle of between 25 and 60 degrees relative to one another and defining respective intersection points, the first variable angle being present in at least two distinct values lying between 25 and 60 degrees;
• heating the metallic grid and a composite laminate skin having a plurality of ply layers comprising a plurality of tapes;
• and
• positioning the composite laminate skin adjacent at least one surface of the metallic grid and permitting the two to return to ambient temperature to define the glueless grid and skin assembly.