Large composite structures and a method for production of large composite structures incorporating a resin distribution network

A method of forming a composite structure comprising:

• providing a core having a peripheral surface and a feeder channel formed to lie across at least a portion of said peripheral surface of said core, said feeder channel having a first cross-sectional area;
• providing a resin distribution network adjacent at least a portion of said peripheral surface and in fluid communication with said feeder channel in said peripheral surface, said resin distribution network comprising a network of grooves formed in said peripheral surface of said core extending from said feeder channel, each of said grooves having a second cross-sectional area smaller than the first cross-sectional area of the feeder channel;
• covering at least a portion of said core and said resin distribution network with a fiber material;
• providing a forming structure, at least a first portion of said forming structure comprising a mold and at least a further portion of said forming structure comprising a flexible portion collapsible under vacuum against an adjacent portion of said core;
• sealing said core and said fiber material in said forming structure;
• connecting a source of uncured resin directly to said feeder channel through said forming structure;
• connecting an interior of said forming structure to a vacuum outlet;
• forcing said uncured resin initially through said feeder channel and said resin distribution network to said vacuum outlet to fill the interior of said forming structure between said core and said forming structure to impregnate said fiber material;
• wherein said feeder channel and said distribution network are sized and arranged to allow said uncured resin to completely fill said fiber material covering said core prior to curing;
• and
• curing said uncured resin to form a composite structure.