Tool for forming a composite member

A method of forming a composite assembly from an uncured composite member, a second composite member, and a cured composite member, the method comprising:

• applying pressure and heat with a compaction tool to a portion of the uncured composite member to decrease a thickness of the portion while leaving unchanged a thickness of at least another portion of the uncured composite member, the heat applied with the compaction tool being at a temperature less than a curing temperature of the uncured composite member;
• inserting the cured composite member between, and in contact with, the portion of the uncured composite member and the second composite member;
• and
• curing the uncured, second, and cured composite members to form the composite assembly after applying pressure and heat.

A method of forming a composite assembly from an uncured composite member, a second composite member, and a cured composite member, the method comprising:

• applying pressure and heat with a compaction tool to a web of the uncured composite member having a C-shaped cross-sectional shape of the uncured composite member to decrease a thickness of a segment of the web, the heat applied with the compaction tool being at a temperature less than a curing temperature of the uncured composite member;
• inserting the cured composite member between, and in contact with, the portion of the uncured composite member and the second composite member;
• and
• heating the uncured, second, and cured composite members to cure the uncured and second composite members and to form the composite assembly after applying pressure and heat.