Composite structure having thermoplastic radius filler

A method of manufacturing a cured composite structure, comprising:

• providing a plurality of radius filler segments, each having breakaway tabs interconnecting the radius filler segments, the breakaway tabs being located at spaced intervals along the length of adjacent pairs of radius filler segments, and extending between side edges of adjacent radius filler segments, and being separable from the radius filler segments;
• inserting the plurality of radius filler segments into a radius cavity extending along a length of an uncured composite base member to form an uncured structural assembly, the plurality of radius filler segments being in end-to-end arrangement within the radius cavity and each having opposing segment ends and being formed of a thermoplastic material;
• heating the structural assembly at least to a base member cure temperature that is at least as high as the temperature of the thermoplastic material at which the segment ends of end-to-end pairs of the plurality of radius filler segments fuse together and form a continuous radius filler element that extends along the length of the composite base member;
• and
• allowing the structural assembly to cure to form a cured composite structure.