A building panel is constructed of a corrugated material. The panel can be folded into a U-shaped configuration. Successive folded panels can be coupled together using complementary shaped corrugations to fix panels in position relative to each other. Shaped connectors can be used to connect building panels in one plane to building panels in another plane.

A composite element and a method of manufacturing the same. The composite element comprises a first skin plate and second skin plate, which are manufactured as separate pieces and are assembled in a separate phase. At least the first skin plate comprises several protrusions on an outer surface of the plate. The protrusions serve as local stiffeners and are further stiffened by means of one or more additional composite structures arranged inside the protrusions.

A building panel is constructed of a corrugated material. The panel can be folded into a U-shaped configuration. Successive folded panels can be coupled together using complementary shaped corrugations to fix panels in position relative to each other. Shaped connectors can be used to connect building panels in one plane to building panels in another plane.

Techniques for providing custom formed panels for transport structures including vehicles and aircraft are disclosed. In one aspect of the disclosure, a panel for a transport structure includes a first face sheet, a second face sheet arranged opposite the first face sheet, the second face sheet comprising a different geometrical profile than the first face sheet to define a space between the first and second face sheets having a variable thickness, a core configured to occupy the space. In another aspect, a node can be additively manufactured to form the custom panels by engaging opposing face sheets. The node has an inlet port for providing a foam-like substance into the space between the face sheets to thereafter solidify into a core.

A composite structure for a building that includes at least one structural panel and at least one metal corrugated panel, where the at least one structural panel is secured to said at least one metal corrugated panel.

Embodiments of the invention relate to structural panel systems, and in particular in-frame fluted panel systems. The in-frame fluted panel systems allow for improved strength and/or ductility within a reduced wall thickness by installing the fluted panels within the framing of the support members in various configurations. The in-frame fluted panel systems further allows for easier construction and lower costs than conventional systems that have fluted panels located outside of the support members.

A method of manufacturing includes providing a continuous flat cover to an assembly line, where the assembly line includes a conveying means. The method also includes applying a flowable reaction material continuously to the flat cover, where the reaction mixture is configured to expand within the flat cover. The method also includes welding the continuous flat cover around the reaction mixture to form an initial profile element. The method also includes cutting the initial profile element, continuously along the assembly line, to form one or more profile elements. Each of the one or more profile elements is a portion of the initial profile element, and each of the one or more profile elements includes a geometry for conforming with a construction component.

In one implementation, a metal deck is provided that includes one or more deck components formed in a contiguous metal sheet. Each of the deck components includes one or more folded ribs formed along the length of the metal deck. Each of the one or more folded ribs are configured such that one or more trusses of a building may fit between the one or more folded ribs. The metal deck may be used to complete the structural diaphragm without using concrete.

A panelized building system and method of construction utilizing a rigid framing combined with foam insulation is disclosed. The system may include a metal roof panel, at least one metal wall panel, a floor panel, at least one metal corner post and at least one foundational component. A single layer of foam insulation encapsulates partially fills a rigid framing and may be molded against a non-stick surface or bonded to an exterior building material. In either case, a single monolithic piece is formed. A utility cavity may be formed interior to the single layer of foam insulation. The exterior face may be textured, undulated, radiused, or shaped in myriad ways.

A panelized building system and method of construction utilizing a rigid framing combined with foam insulation is disclosed. The system may include a metal roof panel, at least one metal wall panel, a floor panel, at least one metal corner post and at least one foundational component. A single layer of foam insulation encapsulates partially fills a rigid framing and may be molded against a non-stick surface or bonded to an exterior building material. In either case, a single monolithic piece is formed. A utility cavity may be formed interior to the single layer of foam insulation. The exterior face may be textured, undulated, radiused, or shaped in myriad ways.