Method of assembling a single piece co-cured structure

A method for manufacturing a composite structure comprising:

• providing a plurality of forms having a foam core surrounded by a membrane, wherein the plurality of forms are pressurizable;
• providing a frame having at least one shaping surface;
• positioning sections of composite material between the plurality of forms;
• placing an exterior composite material between the plurality of forms and the at least one shaping surface of the frame;
• enclosing the plurality of forms and the composite material into a frame;
• selectively pressurizing the plurality of pressurizable forms while the composite material is between the plurality of forms;
• curing the composite material;
• and
• removing the plurality of forms from the composite structure.

A process for manufacturing a composite structure comprising:

• providing a pressurizable fuselage form, wherein the form has a plurality of stiffener channels;
• placing composite stiffener material in the stiffener channels;
• wrapping a composite material around the fuselage form and the composite stiffener material;
• substantially enclosing the fuselage form in a frame having at least one shaping surface;
• pressurizing the pressurizable fuselage form, such that the composite material is biased against the at least one shaping surface;
• curing the composite material;
• and
• removing the form from the composite structure.

A process for manufacturing a composite fuselage comprising:

• providing a pressurizable fuselage form, wherein the pressurizable fuselage form is surrounded by a plurality of caul sheets, and wherein the caul sheets have a plurality of stiffener channels;
• placing composite stiffener material in the stiffener channels;
• winding a composite material around the pressurizable fuselage form and the composite stiffener material;
• substantially enclosing the fuselage form with the wound composite material thereon in a frame having at least one shaping surface;
• pressurizing the pressurizable fuselage form while enclosed in the frame;
• co-curing the composite material;
• and removing the form and caul sheets from the composite fuselage while permitting the stiffener to remain.

A method for manufacturing a composite structure comprising:

• substantially surrounding a pressurizable form with a sheet of composite material, wherein a caul sheet is disposed on the form, wherein the form includes a shrinkable foam core surrounded by a flexible membrane;
• placing the pressurizable form and the composite material into a frame, wherein the frame has at least one shaping surface;
• pressurizing the pressurizable form, such that the composite material and caul sheet are biased against the shaping surface;
• curing the composite material;
• and
• removing the form and the caul sheet from the cured composite structure.