Cellular composite grid-stiffened structure

A method for creating a cellular composite structure, the structure including a grid including a plurality of intersecting ribs, a plurality of rib intersections defining a plurality of rib segments, and a plurality of contiguous rib walls, the method comprising:

• orienting first ones of the ribs in a non-crossing pattern with respect to each other and angularly oriented with respect to second ones of the ribs such that segments of the first and second ones of the ribs create a plurality of contiguous rib walls defining a closed geometric shape such that individual ones of the plurality of the contiguous rib walls share selected ones of the rib intersections, with each of the contiguous walls defining one of a plurality of composite structure cavities;
• stacking at least first, second, and third layers of a resin pre-impregnated material to create individual ones of a plurality of cap members, the first, second, and third layers of each cap member together defining an end wall;
• forming a riser wall individually from each of the first, second, and third layers oriented perpendicular to the end wall, such that only a portion of the first layer that does not overlap the second and third layers is used to form a first section of the riser wall, and such that only a portion of the second layer that does not overlap the first and third layers is used to form a second section of the riser wall, the second section being spaced apart from the first section, and further such that only a portion of the third layer that does not overlap the first and second layers is used to form a third section of the riser wall, the third section being spaced apart from the first and second sections;
• positioning individual ones of the plurality of cap members within selected ones of the plurality of cavities having each said riser wall in sliding contact with an individual one of the segments of one of the cavities;
• and
• co-curing the cap members and the plurality of intersecting ribs to adhesively bond the riser walls and the rib segments.