Inflatables-Based Process for Creating Multi-Layer Internal Reinforcements

A system for forming a structural component for a vehicle, comprising:

• a component including a first hollow passage defined by an interior surface of the component;
• a first inflatable bladder insertable into the first hollow passage of the component, wherein the first inflatable bladder and the interior surface of the component define a first cavity within the first hollow passage;
• and
• a second inflatable bladder insertable into the first hollow passage, wherein the second inflatable bladder defines a second cavity within the first hollow passage.

A structural component for a vehicle, comprising:

• a component including an interior surface defining a first hollow passage;
• a first structural reinforcement contacting the interior surface of the component, the first structural reinforcement formed of a first polymer resin foam;
• and
• a second structural reinforcement contacting the first structural reinforcement, the second structural reinforcement formed of a second polymer resin foam,
• wherein the first structural reinforcement and the second structural reinforcement for a multilayer structural reinforcement, and the component define a cross-section and the multilayer structural reinforcement partially fill the cross-section.