Multiple, thick graphite fabric production

Resin impregnated graphite materials used in the aerospace industry, such as to make wing, and empennage and fuselage panels, are constructed in such a way that there is a lower labor content, the probability of delamination is greatly reduced, and there is less chance for damage of the components since there is less handling during construction. A fabric is woven having a thickness in the range of about 0.25-1.0 inches. The fabric preferably has two face and two back warp ends, a plurality of stuffer warp ends between the face and back, and binder warp ends interconnecting the face and back warp ends. The binder warp ends are preferably aramid, and the other warp ends preferably graphite. Pure carbon fiber inclusions may be provided in the interior of the fabric, and even in the face and back, and are connected up to a source of electricity to heat the fabric from within to produce a uniform resin flow. One or more layers of the fabric are impregnated with resin and formed into a desired shape by placing one or more layers into a die, bending around a radius to form a curved portion without wrinkling, folding, or pleating of the fabric of the layers, and then the fabric is further treated. Further treatment includes heating and curing, heating being effected both from the exterior and from the interior due to the pure carbon fiber inclusions.