A vehicle body may have a skeleton formed by a plurality of overlapping layers bonded to each other. Each of the plurality of overlapping layers may be fabricated from a continuous fiber coated with a matrix material. A trajectory of the continuous fiber may be different between adjacent layers of the plurality of overlapping layers.

A vehicle body may have a skeleton formed by a plurality of overlapping layers bonded to each other. Each of the plurality of overlapping layers may be fabricated from a continuous fiber coated with a matrix material. A trajectory of the continuous fiber may be different between adjacent layers of the plurality of overlapping layers.

Methods and structures are disclosed. An example method includes: rotating a tubular mandrel about a longitudinal axis of the tubular mandrel; depositing a composite material on an inner surface of the tubular mandrel to form a composite tubular member on the inner surface of the tubular mandrel; inserting and expanding an inner expandable mandrel within the composite tubular member to cause the inner expandable mandrel to press the composite tubular member against the inner surface of the tubular mandrel; curing the composite tubular member; removing the inner expandable mandrel; placing a frame within the composite tubular member; and removing the tubular mandrel so as to obtain the composite tubular member with the frame placed therein.

Methods and structures are disclosed. An example method includes: rotating a tubular mandrel about a longitudinal axis of the tubular mandrel; depositing a composite material on an inner surface of the tubular mandrel to form a composite tubular member on the inner surface of the tubular mandrel; inserting and expanding an inner expandable mandrel within the composite tubular member to cause the inner expandable mandrel to press the composite tubular member against the inner surface of the tubular mandrel; curing the composite tubular member; removing the inner expandable mandrel; placing a frame within the composite tubular member; and removing the tubular mandrel so as to obtain the composite tubular member with the frame placed therein.

A vehicle body may have an internal skeleton, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. At least one of the plurality of continuous fibers is in tension and has differing levels of tension along its length.

A vehicle body may have an internal skeleton, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. At least one of the plurality of continuous fibers is in tension and has differing levels of tension along its length.

A vehicle body may have an internal skeleton, and a skin fabricated in-situ over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. The plurality of continuous fibers may include at least one electrically conductive wire interwoven with others of the plurality of continuous fibers. The at least one electrically conductive wire may be configured to function as at least one of a heater and a strain gauge.

A vehicle body may have an internal skeleton, and a skin fabricated in-situ over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. The plurality of continuous fibers may include at least one electrically conductive wire interwoven with others of the plurality of continuous fibers. The at least one electrically conductive wire may be configured to function as at least one of a heater and a strain gauge.

A vehicle body may have an internal skeleton forming a wing shape and a fuselage shape, and a skin fabricated in-situ over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers at least partially coated with the matrix material. The plurality of continuous fibers may extend from the wing shape over the fuselage shape.

A vehicle body may have an internal skeleton forming a wing shape and a fuselage shape, and a skin fabricated in-situ over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers at least partially coated with the matrix material. The plurality of continuous fibers may extend from the wing shape over the fuselage shape.