Resin coated radius fillers and method of making the same

A method of forming a resin coated radius filler comprising:

• supplying a continuous fibrous braid to be coated;
• providing a heated resin formulation in a container, said container having a bottom wall and a deformable grommet positioned through said bottom wall, said grommet being provided with a through hole that is sized to enable the fibrous braid to pass through and at the same time to control the amount of resin deposited onto the outer surface of the fibrous braid;
• and
• pulling the continuous fibrous braid through the resin formulation and out through the grommet, whereby an amount of resin is deposited onto the outer surface of the fibrous braid but the core of the fibrous braid remains free of resin,
• wherein the fibrous braided is comprised of a plurality of fiber strands intertwined in a braid pattern
• wherein the fibrous braid's contact time with the resin formulation is controlled by controlling the line speed and the resin level of the resin formulation in the container, and
• wherein the viscosity of the resin formulation is controlled to enable the formation of a resin coating with substantially uniform thickness.