Systems and Methods for Fabricating Composite Fiberglass Laminate Articles

A method of fabricating a composite article comprising the steps of:

• providing a plurality of primary panels, where
• each primary panel defines at least one edge, a first surface, and a second surface, and
• at least one of the primary panels is a flat primary panel the first and second surfaces of which are substantially planar and substantially parallel;
• providing a plurality of secondary panels, where each secondary panel defines at least one edge, a first surface, and a second surface;
• providing a plurality of tertiary panels, where each tertiary panel defines at least one edge, a first surface, and a second surface;
• bending the at least one flat primary panel such that the first and second surfaces thereof are no longer substantially planar;
• arranging the plurality of primary panels such that
• at least one edge of one of each the primary panels is adjacent to at least one edge of another of the primary panels, and
• the primary panels conform to the shape of the composite article;
• forming an inner skin by joining the adjacent edge portions of adjacent primary panels;
• after the inner skin has been formed, forming a core by arranging the plurality of secondary panels such that
• the first surfaces of at least some of the secondary panels are adjacent to the second surfaces of at least some of the primary panels, and
• at least one edge of each of the secondary panels is adjacent to at least one edge of another of the secondary panels;
• joining the second surfaces of at least some of the primary panels to the first surfaces of at least some of the secondary panels adjacent thereto;
• after the core has been formed, forming an outer skin by arranging the plurality of tertiary panels such that
• the first surfaces of at least some of the tertiary panels are adjacent to the second surfaces of at least some of the secondary panels, and
• at least one edge of each of the tertiary panels is adjacent to at least one edge of another of the tertiary panels;
• joining the second surfaces of at least some of the secondary panels to the first surfaces of the tertiary panels adjacent thereto;
• and
• applying material to the tertiary panels to finish the outer skin of the composite article.