Formed core sandwich structure and method and system for making same

A method of manufacturing a core sandwich structure, comprising:

• forming a non-honeycomb core having a first and a second core each having a plurality of inwardly and outwardly projecting bonding lands and at least two non-parallel directions of corrugation, wherein a plurality of the inwardly projecting bonding lands of the first core are bonded to a plurality of the inwardly projecting bonding lands of the second core, the first and second cores each being a continuous sheet of material;
• and
• forming a bulge on at least a portion of the inwardly projecting bonding lands of the first core and a dimple on at least a portion of the inwardly projecting bonding lands of the second core, positioning bulges at least partially within corresponding dimples, wherein each dimple extends inwardly relative to its bonding land and each bulge protudes outwardly relative to its bonding land;
• and
• securing first and second sheets to the first and second cores to form the core sandwich structure wherein the first and second cores are continuous sheets in the core sandwich structure.

A method of manufacturing a multi-layer sandwich structure, comprising:

• forming a non-honeycomb core having a first core structure and a second core structure each having a plurality of inwardly and outwardly projecting bonding lands and at least two non-parallel directions of corrugation, the first and second cores each being a continuous sheet of material;
• forming, prior to bonding, a bulge on at least a portion of the inwardly projecting lands of the first core structure and a dimple on at least a portion of the inwardly projecting lands of the second core structure, wherein bulges are received at least partially within corresponding dimples, wherein each of a dimple extends inwardly relative to its bonding land and each of a bulge protrudes outwardly relative to its bonding land;
• bonding the plurality of the inwardly projecting lands of the first core structure to the plurality of the inwardly projecting lands of the second core structure;
• securing first and second sheets to the first and second cores to form the multi-layer sandwich structure wherein the first and second cores are continuous sheets in the multi-layer sandwich structure.