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A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross sup

A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect. Subjecting these to a curing system functions to consolidate the cross supports and multi-layered nodes to produce the composite lattice support structure.

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1. A method for forming a composite lattice support structure, said method comprising: forming a first cross support comprising a fiber-based composite material, said first cross support having one or more selective individual fiber filaments layered in an offset configuration;forming a second cross

1. A method for forming a composite lattice support structure, said method comprising: forming a first cross support comprising a fiber-based composite material, said first cross support having one or more selective individual fiber filaments layered in an offset configuration;forming a second cross support comprising a fiber-based composite material that intersects said first cross support, said second cross support having one or more selective individual fiber filaments layered in an offset configuration; andforming one or more multi-layered nodes where said first and second cross supports intersect, with said one or more selective individual fiber filaments of said first cross support intersecting and being layered with said one or more individual selective fiber filaments of said second cross support to define said multi-layered nodes,wherein said first and second cross supports define a lattice support structure having a seamless three-dimensional geometry about a centerline. 2. The method of claim 1, wherein said forming said first and second cross supports comprises laying up fiber filament to provide each of said first and second cross supports with multiple layers, respectively, wherein said multi-layered nodes comprise at least two layers of said first cross support separated by at least one layer of said second cross support. 3. The method of claim 1, wherein said forming said first and second cross supports comprises laying up fiber filament to provide each of said first and second cross supports with multiple layers, respectively, wherein said multi-layered nodes comprise at least two layers of said second cross support separated by at least one layer of said first cross support. 4. The method of claim 1, further comprising forming a third cross support comprising a fiber-based composite material that intersects at least one of said first and second cross supports. 5. The method of claim 4, further comprising forming one or more multi-layered nodes where said first and second and third cross supports intersect, with one or more selective individual fiber filaments from each of said first and second and third cross supports intersecting and being layered to define said multi-layered nodes. 6. The method of claim 1, further comprising forming at least one of the first and second cross supports on a curve from node to node to provide non-linear path loading along said first and second cross supports. 7. The method of claim 4, wherein said forming a third cross support comprises laying up fiber filament to provide said third cross support with multiple layers, wherein said multi-layered nodes comprise at least one layer of said third cross support layered with at least one layer of at least one of said first and second cross supports. 8. The method of claim 4, further comprising forming said third cross support on a curve from node to node to provide non-linear path loading. 9. The method of claim 1, wherein said forming a first cross support comprises forming a first helical cross support. 10. The method of claim 9, wherein said forming a second cross support comprises forming a second helical cross support. 11. The method of claim 10, wherein said second helical cross support is oriented in a reverse direction from that of said first helical cross support. 12. The method of claim 4, further comprising forming said first, second and third cross supports in an orientation selected from the group consisting of a helical orientation, a longitudinal orientation, and a lateral orientation. 13. The method of claim 4, further comprising forming at least one of said first, second and third cross supports in a longitudinal orientation, and forming at least two of said first, second and third cross supports in a helical orientation. 14. The method of claim 4, further comprising forming each of said first, second and third cross supports in a helical orientation. 15. The method of claim 4, further comprising forming at least one of said first, second and third cross supports in a circumferential or lateral orientation. 16. The method of claim 1, wherein said lattice support structure comprises a generally cylindrical shape, and a plurality of helical cross supports. 17. The method of claim 16, wherein said lattice support structure of generally cylindrical shape further comprises a plurality of cross supports selected from longitudinal cross supports and lateral cross supports. 18. The method of claim 16, wherein at least some of either of said longitudinal cross supports and lateral cross supports are asymmetrically spaced apart from one another. 19. The method of claim 16, wherein at least some of either of said longitudinal cross supports and lateral cross supports are grouped together within a given radial area to provide selective reinforcement of certain segments of said lattice support structure. 20. The method of claim 16, wherein a first radial area comprises a greater concentration of said longitudinal cross supports than a different second radial area of equal size. 21. The method of claim 16, wherein at least some of said plurality of helical cross supports comprise a different pitch. 22. The method of claim 10, wherein said second helical support comprises a different pitch than said first helical support. 23. The method of claim 1, further comprising forming a plurality of cross supports comprising a fiber-based composite material that intersect to form a plurality of multi-layered nodes, in accordance with a pre-determined cross support density. 24. The method of claim 1, wherein said first cross support is part of a plurality of helical cross supports, and wherein said second cross support is part of a plurality of reverse helical cross supports, said lattice support structure comprising a different number of said helical and reverse helical cross supports to provide said lattice support structure for increased strength in a given direction. 25. The method of claim 1, wherein said first cross support is part of a plurality of helical cross supports, at least some of said plurality of helical cross supports having a different orientation. 26. The method of claim 1, wherein said first cross support is part of a plurality of helical cross supports, at least some of said plurality of helical cross supports being unevenly spaced with respect to one another. 27. The method of claim 1, wherein said first cross support comprises a helical cross support having a variable pitch. 28. The method of claim 1, further comprising configuring said lattice support structure to comprise a circumferentially closed geometry. 29. The method of claim 1, wherein said lattice support structure comprises a constant load path throughout. 30. The method of claim 1, wherein said lattice support structure comprises a variable shape in the axial direction as measured radially outward from a centerline. 31. The method of claim 1, wherein said lattice support structure comprises a cross-sectional geometry selected from the group consisting of linear, nonlinear, and a combination of these. 32. The method of claim 4, further comprising forming said cross supports with a specific, pre-determined cross-sectional geometry, said cross-sectional geometry of said cross supports being specifically controlled through a corresponding cross-sectional geometry of said channels of said rigid mold. 33. The method of claim 32, wherein a surface of said cross support oriented away from a centerline of said lattice support structure conforms to a general geometry of said lattice support structure through pressurized consolidation of said fiber filaments, and wherein a remaining surface of said cross support conforms to a shape of said channel of said rigid mold to provide said cross-sectional geometry. 34. The method of claim 32, wherein at least one of said cross supports comprises a different cross-sectional geometry than that of another of said cross supports. 35. The method of claim 32, wherein said cross-sectional geometry of said cross supports is selected from the group consisting of square, triangular, t-shaped, I-beam shaped, rectangular, circular, oval. 36. The method of claim 32, wherein said cross-sectional geometry of said cross supports comprises a cross-sectional geometry having surfaces selected from the group consisting of linear, nonlinear, and a combination of these. 37. The method of claim 1, wherein said forming said first and second cross supports, and said forming said multi-layered nodes comprises consolidating said fiber filaments in the presence of resin, heat and pressure. 38. The method of claim 1, further comprising forming a circumferential collar about an end of said lattice support structure, said circumferential collar comprising fiber filaments integrally formed and consolidated with said fiber filaments of said first and second cross supports. 39. The method of claim 1, further comprising forming a plurality of cross supports to concentrate strength in a given location and direction of said lattice support structure. 40. The method of claim 1, further comprising configuring said lattice support structure such that, in the event of localized breakage in one of said cross supports resulting in reduced performance or failure, a load path is changed and transferred to one or more unbroken cross support to compensate for said reduced performance or failure. 41. A method for forming a composite lattice support structure having a plurality of cross supports intersecting one another to form a plurality of multi-layered nodes, said method comprising: obtaining a rigid mold having a plurality of rigid channels, at least some of said plurality of rigid channels intersecting at strategic locations;laying up a fiber material in an off-set configuration, in the presence of a resin, within said channels; andconsolidating said lay-up to form a plurality of composite cross supports having a pre-determined lateral cross-sectional area controlled by a cross-sectional area of said channels, and that intersect to form a plurality of nodes,said channels containing said lay-up during said consolidating, and facilitating formation of said cross supports and multi-layered nodes. 42. The method of claim 41, wherein at least some of said cross supports are curved from node to node to provide non-linear path loading along said cross supports. 43. The method of claim 41, wherein said rigid mold comprises a rigid mandrel having a plurality of grooves formed in a surface, said grooves defining a number, an orientation, a location and a density of said cross supports and said nodes as part of said formed composite lattice support structure. 44. The method of claim 41, wherein said rigid mold comprises a collapsible mandrel, and wherein said method further comprises collapsing said mandrel to facilitate easy removal of said formed lattice support structure from said rigid mold after consolidation. 45. The method of claim 41, wherein said channels of said rigid mold comprise a specific, pre-determined cross-sectional area that provide said cross supports with a corresponding cross-sectional area. 46. The method of claim 41, wherein said laying up a fiber material comprises depositing fiber filaments within said channels in a unidirectional orientation through at least some of said channel intersections so said fiber materials maintain a unidirectional path through said formed nodes. 47. The method of claim 41, wherein said laying up a fiber material, in the presence of a resin, prior to consolidation and in an uncured state, provides a seamless three-dimensional green lattice support structure prior to said consolidating. 48. The method of claim 41, wherein said laying up a fiber material, in the presence of a resin, comprises winding a fiber-based tow onto said rigid mold in accordance with a pre-determined winding process, said channels providing a secure pathway for said tow. 49. The method of claim 48, wherein said fiber-based tow comprises a preimpregnated tow. 50. The method of claim 41, wherein said consolidating comprises: drawing a vacuum about said lay-up to increase a pressure acting on said lay-up, said pressure causing said fiber material to assume a geometry of said channels; andsubjecting said lay-up to an elevated temperature for a given time. 51. The method of claim 41, wherein said consolidating comprises: covering said lay-up, in an uncured state, with a vacuum enclosure;placing said lay-up as covered with said vacuum enclosure in a curing system; andcuring said lay-up within said curing system in the presence of a vacuum, heat and pressure,said vacuum enclosure compacting said fiber material, in the presence of said resin, within said channels of said rigid mold, and causing said fiber material to assume a geometry of said channels. 52. The method of claim 41, further comprising forming a plurality of multi-layered nodes from layered or overlapping fiber filaments of at least two cross supports selected from the group consisting of non-straight cross supports, helical cross supports, longitudinal cross supports, axial cross supports and lateral or circumferential cross supports. 53. A method for preparing a green composite three-dimensional lattice preform configuration for use in forming a seamless three-dimensional geometric lattice support structure, said method comprising: obtaining a rigid mold having one or more channels associated therewith;obtaining a fiber material;depositing said fiber material, in the presence of a resin, onto said rigid mold within said channels;causing at least some of said fiber materials to be oriented in a three-dimensional orientation about a centerline; andcausing one or more of said fiber materials to intersect and layer to form a lattice structure, and to form a plurality of multi-layered nodeswherein said at least some of the fiber materials layer in an offset configuration. 54. The method of claim 53, further comprising causing additional fiber materials to extend in a lateral, circumferential or axial orientation with respect to said centerline, which additional fiber materials may be caused to intersect and be layered with any other present fiber materials. 55. A system for forming complex three-dimensional composite lattice support structures, said system comprising: a rigid mold having a plurality of rigid channels, at least some of said plurality of rigid channels intersecting at strategic locations;a lay-up of fiber material, in the presence of a resin, within said channels, said fiber material comprising fiber filaments that are layered in an off-set configuration with one another and that intersect at said strategic locations; anda curing system for consolidating said lay-up to form a plurality of cross supports and multi-layered nodes. 56. The method of claim 1, further comprising curing the composite lattice support structure at a temperature of 250-350° F. under nitrogen gas at a pressure of 90-150 psi for a period of 10-240 minutes. 57. The method of claim 1, wherein the multi-layered nodes are flattened in shape. 58. The method of claim 1, further comprising compacting the fiber-based composite material of the first and second cross supports into a rigid channel of a mandrel. 59. The method of claim 4, wherein the composite lattice support structure includes at least two different types of multi-layered nodes including a first multi-layered node formed where three cross supports intersect, said three cross supports are a first longitudinal cross support, a first clockwise helical cross support, and a first counterclockwise helical cross support, and a second multi-layered node formed where two helical cross supports intersect, said two helical cross supports are a second clockwise helical cross support and a second counterclockwise helical cross support; wherein the first multi-layered node and the second multi-layered node are present in a 1:1 ratio. 60. The method of claim 41, further comprising curing the composite lattice support structure at a temperature of 250-350° F. under nitrogen gas at a pressure of 90-150 psi for a period of 10-240 minutes. 61. The method of claim 41, wherein the multi-layered nodes are flattened in shape. 62. The method of claim 41, wherein the composite lattice support structure includes at least two different types of multi-layered nodes including a first multi-layered node formed where three cross supports intersect, said three cross supports are a first longitudinal cross support, a first clockwise helical cross support, and a first counterclockwise helical cross support, and a second multi-layered node formed where two helical cross supports intersect, said two helical cross supports are a second clockwise helical cross support and a second counterclockwise helical cross support; wherein the first multi-layered node and the second multi-layered node are present in a 1:1 ratio. 63. The method of claim 53, wherein the green composite three-dimensional lattice preform configuration includes at least two different types of multi-layered nodes including a first multi-layered node formed where three cross supports intersect, said three cross supports are a first longitudinal cross support, a first clockwise helical cross support, and a first counterclockwise helical cross support, and a second multi-layered node formed where two helical cross supports intersect, said two helical cross supports are a second clockwise helical cross support and a second counterclockwise helical cross support; wherein the first multi-layered node and the second multi-layered node are present in a 1:1 ratio. 64. The system of claim 55, wherein the curing system cures the composite lattice support structure at a temperature of 250-350° F. under nitrogen gas at a pressure of 90-150 psi for a period of 10-240 minutes. 65. The system of claim 55, wherein the multi-layered nodes are flattened in shape. 66. The system of claim 55, wherein the complex three-dimensional composite lattice support structures include at least two different types of multi-layered nodes including a first multi-layered node formed where three cross supports intersect, said three cross supports are a first longitudinal cross support, a first clockwise helical cross support, and a first counterclockwise helical cross support, and a second multi-layered node formed where two helical cross supports intersect, said two helical cross supports are a second clockwise helical cross support and a second counterclockwise helical cross support; wherein the first multi-layered node and the second multi-layered node are present in a 1:1 ratio.