METHOD OF FORMING A UNITARY COMPOSITE STRUCTURE

A method of manufacturing a unitary energy absorbing structure for a vehicle includes providing a first mold having a cavity receiving a first mandrel and a second mold having a cavity receiving a second mandrel. At least one mandrel segment is positioned in the first mold cavity and cooperates with the first mandrel. One or more layers of composite material at least partially cover the first mold cavity, first mandrel, at least one mandrel segment and second mold. The unitary structure is formed from the first layer, the second layer and the third layer of composite material with the first mandrel, the at least one mandrel segment and the second mandrel in the first mold and the second mold.