The present disclosure provides a method of manufacturing a composite sandwich panel having a core formed of a plurality of cells extending vertically between a first skin and a second skin. The method includes creating at least one first strip and a second strip from a temporary material, each strip having at least one cavity having a succession of aligned half-cells, lining the cavity of the first strip with a fibrous ply, assembling the first strip and the second strip by interlocking the cavity of the first strip with the cavity of the second strip and trapping the fibrous ply therebetween, and trimming excess temporary material of the entirety of the strips formed during the preceding assembly step so as to form a new cavity which forms a succession of aligned half-cells.

The present disclosure provides a method of manufacturing a composite sandwich panel having a core formed of a plurality of cells extending vertically between a first skin and a second skin. The method includes creating at least one first strip and a second strip from a temporary material, each strip having at least one cavity having a succession of aligned half-cells, lining the cavity of the first strip with a fibrous ply, assembling the first strip and the second strip by interlocking the cavity of the first strip with the cavity of the second strip and trapping the fibrous ply therebetween, and trimming excess temporary material of the entirety of the strips formed during the preceding assembly step so as to form a new cavity which forms a succession of aligned half-cells.

Described herein is a substrate including a central longitudinal axis, a first support web, and a second support web. A sinuous web may be positioned between the first support web and the second support web. The sinuous web may include transverse web portions and bridging web portions, where the bridging web portions alternatively connect ends of adjacent transverse web portions. The sinuous web may be connected to the first support web by support legs extending between bridging web portions and a surface of the first support web. The sinuous web may be connected to the second support web by support legs extending between bridging web portions and a surface of the second support web. A support leg length to distance between transverse web portions ratio may be from about 1.0 to about 4.0.

Described herein is a substrate including a central longitudinal axis, a first support web, and a second support web. A sinuous web may be positioned between the first support web and the second support web. The sinuous web may include transverse web portions and bridging web portions, where the bridging web portions alternatively connect ends of adjacent transverse web portions. The sinuous web may be connected to the first support web by support legs extending between bridging web portions and a surface of the first support web. The sinuous web may be connected to the second support web by support legs extending between bridging web portions and a surface of the second support web. A support leg length to distance between transverse web portions ratio may be from about 1.0 to about 4.0.