Composite sandwich structure and method for making same

A core for a sandwich structure which has multi-ply laminate ribs separated by voids is made as an integral unit in one single curing step. Tooling blocks corresponding to the voids are first wrapped by strips of prepreg layup equal to one half of each rib laminate so a continuous wall of prepreg material is formed around the tooling blocks. The wrapped tooling blocks are next pressed together laterally, like tiles, so adjoining walls from two tooling blocks are joined. The assembly is then cured by conventional methods, and afterwards the tooling blocks are removed so voids are formed. The ribs can be provided with integral tabs forming bonding areas for face sheets, and face sheets may be co-cured with the core ribs. The new core design is suitable for discrete ribcores used in space telescopes and reflector panels, where quasiisotropic properties and zero coefficient of thermal expansion are required.