Structural panel

A cast structural panel comprising:

• a first plate having an exterior first plate surface and an interior first plate surface, the interior first plate surface disposed completely in a first plane;
• a second plate having an exterior second plate surface and an interior second plate surface, the interior second plate surface disposed completely in a second plane and faced toward the first interior plated surface;
• a first tray integral with the first plate, the first tray comprised of an array of hollow first pyramids joined at their bases to the first plate, the first pyramids contacting one another along their basal edges, the sides of the pyramids defining one or more apertures;
• a second tray integal with the second plate, the second tray comprised of an array of hollow second pyramids joined at their bases to the second plate, the second pyramids contacting one another along their basal edges, the sides of the second pyramids defining one or more apertures;
• the array of first pyramids and the array of second pyramids meshing together so that edges of the first pyramids contact edges of the second pyramids, the first and second pyramids integrally joined to each other at areas of contact;
• the plates and trays together forming a one-piece, continuous casting.

A one-piece vehicle body portion comprised of a plurality of structural panels integrally formed with one another, each structural panel comprising:

• a first plate having an exterior first plate surface and an interior first plate surface, the interior first plate surface disposed completely in a first plane;
• a second plate having an exterior second plate surface and an interior second plate surface, the interior second plate surface disposed completely in a second plane and faced toward the first interior plated surface;
• a first tray comprised of first pyramids having apertured sides and joined integrally at their bases to the first tray, the first pyramids abutting along their basal edges to form V-shaped valleys between the first pyramids;
• a second tray comprised of second pyramids having apertured sides and joined integrally at their bases to the second tray, the second pyramids abutting along their basal edges to form V-shaped valleys between the second pyramids;
• the first pyramids and the second pyramids fitting closely together and being integrally joined at the areas of contact;
• filler material occupying the pyramids and apertures in the panel so as to form a single continuous body interwoven with the tray.