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A method of forming a unitary, composite structural member, and a member formed in accordance with the process. The process involves stitching a plurality of warp knit panel sections together to generally form a plurality of independent panel sections. The sections are placed within the dies of a mo

A method of forming a unitary, composite structural member, and a member formed in accordance with the process. The process involves stitching a plurality of warp knit panel sections together to generally form a plurality of independent panel sections. The sections are placed within the dies of a molding tool such that a rib portion of each section aligns. Inflatable bladders are then slipped into voids formed in between the various panel sections of the assembly. The bladders are inflated to hold with one another. Resin is then infused into the panels that make up the assembly. The assembly is then cured. When the panels are removed from the molding tool a unitary, complexly shaped, composite structural member is formed.

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1. A method for forming a unitary composite structure, comprising,placing a first, stitched together, multipiece panel of fabric within a tool; placing a second panel of fabric within said tool, said first and second panels having cooperating, longitudinally aligned rib portions interengaged to form

1. A method for forming a unitary composite structure, comprising,placing a first, stitched together, multipiece panel of fabric within a tool; placing a second panel of fabric within said tool, said first and second panels having cooperating, longitudinally aligned rib portions interengaged to form a unitary rib panel when said structure is fully formed; inflating a bladder placed adjacent to said first and second panels of fabric, and adjacent to said rib portions, to urge selected portions of said panels and said rib portions into contact with one another to form a joint there between, and to urge selected areas of said panels into contact with surfaces of said tool as said inflatable bladder is inflated; infusing said panels with a resin; and curing said panels to form said unitary composite structure having an integrally formed joint. 2. The method of claim 1, wherein said step of urging selected areas of said panels into contact with surfaces of said tool comprises urging selected areas of said panels into contact with surfaces of a tool that provides said unitary composite structure with a shape of a final component part.3. The method of claim 1, further comprising the steps:depressurizing said inflatable bladder after said curing step; and removing said inflatable bladder through a hole in said tool. 4. The method of claim 1, wherein said curing is performed within an oven.5. The method of claim 1, wherein the step of using at least one inflatable bladder comprises using an inflatable latex bladder.6. The method of claim 1, wherein the steps of placing said first and second panels of fabric within said tool comprises placing said rib portion of each of said first and second panels adjacent one another such that said rib portions are urged against one another when said inflatable bladder is inflated.7. The method of claim 1, wherein the step of placing said first and second panels of fabric in said tool comprises placing first and second warp-knit fabric panels in said tool.8. The method of claim 1, wherein said bladder is inflated by placing an opening of said bladder in communication with an opening in said tool; andcreating a vacuum within said tool. 9. The method of claim 1, wherein said bladder is inflated by supplying a pressurized fluid to said bladder from a pressurized fluid source.10. The method of claim 1, wherein said rib portions are urged into overlapping contact with one another as the bladder is inflated.11. A method for forming a unitary composite structure, comprising:placing a first section of fabric within a tool; placing a second section of fabric within said tool; each of said first and second sections including interengaging rib portions; using at least one inflatable bladder placed in between said first and second sections of fabric and adjacent to said rib portions to urge selected portions of said first and second sections of fabric into contact with surfaces of said tool, and to urge ends of said rib portions into contact with one another to form an integral rib structure, infusing said first and second sections of fabric with a resin; and curing said sections of fabric at a predetermined temperature for a predetermined period of time to form said unitary composite structure. 12. The method of claim 11, further comprising the steps:forming at least one of said rib portions with at least one hole; depressurizing said inflatable bladder after said curing step; and removing said inflatable bladder through said hole. 13. The method of claim 11, further comprising forming said tool with at least one opening through which said bladder can be removed.14. The method of claim 11, wherein said inflatable bladder is inflated by placing an open end thereof in communication with an opening in said tool; anddepressurizing an interior area of said tool to create vacuum within said tool. 15. The method of claim 11, wherein said inflatable bladder is pressurized by a pressurized fluid supplied through an opening in said inflatable bladder.16. The method of claim 11, wherein the step of using an inflatable bladder comprises using an inflatable latex bladder.17. The method of claim 11, wherein the step of placing first and second sections of fabric within a tool comprises placing first and section sections of warp knit fabric within the tool.18. The method of claim 11, wherein the step of placing first and second sections of fabric within a tool comprises placing first and second sections of a composite material within the tool.