Integrated composite drive shafts

A method of making a composite shaft, the method comprising:

• providing a mandrel having a substantially cylindrical shape and defining an axis;
• installing one or more first inserts along an axial length of the mandrel;
• arranging a first group of axisymmetric composite elements about the axis offset by an angle +α, wherein the first group of composite elements is applied to the mandrel along axial lengths defining narrow portions of a formed composite shaft and the first group of composite elements is applied to the one or more first inserts along axial lengths defining one or more undulating portions of the formed composite shaft;
• installing one or more second inserts along the axial length of mandrel, wherein at least one of the one or more first inserts has a respective second insert installed radially outward therefrom and axially aligned therewith;
• and
• arranging a second group of composite elements arranged about the axis offset by an angle −α to form a web with the first group of composite elements, wherein the second group of composite elements is applied to the first group of composite elements along the axial lengths defining the narrow portions of the formed composite shaft and the second group of composite elements is applied to the one or more second inserts along the axial lengths defining the one or more undulating portions of the formed composite shaft.