Method of making precision geometry advanced composite honeycomb material for spacecraft applications and honeycomb material made thereby

摘要

A method of making precision geometry honeycomb material formed of a composite material and exhibiting dimensional uniformity, is disclosed. Composite material is molded in the cavity of a single-sided female mold to form a first web with a plurality of honeycomb cell portions of the desired cell shape in the web. The details of the cavity mold configuration are captured to form the honeycomb cell portions in the composite material during molding the web by applying pressure to the composite material in the mold with an elastomeric pressure intensifier. The composite material of the web is stabilized as by curing. First and second molded webs are precisely aligned in a fixture and joined together at facing cell nodes thereof by bonding yielding a honeycomb material with superior geometric platform.