High strength composite structure and method of production

A method of making light weight, high strength, heat resistant composite structure, comprising:

• providing a suitably shaped uniformly solid, 3D printed, lightweight polymer core;
• providing a two-part mold shaped to enclose said core;
• laying up one or more layers of resin impregnated aramid fabric onto a lower part of said two-part mold, thereby creating a lower, outer housing;
• laying up one or more layers of resin impregnated carbon fiber fabric onto said lower, outer housing thereby creating a lower inner casing;
• placing said polymer core onto said lower inner casing;
• laying up one or more layers of resin impregnated carbon fiber fabric onto said core thereby creating an upper inner casing;
• laying up one or more layers of resin impregnated aramid fabric onto upper inner casing, thereby creating an upper, outer housing, and thereby completed a laid up composite structure;
• placing an upper part of said two-part mold to connect with said lower part of said two-part mold to enclose said laid up laminated structure;
• curing said two-part mold containing said laid up laminated structure thereby creating a cured composite structure;
• separating said two-part mold;
• and,
• removing said cured composite structure from said two-part mold.