Composite parts, and methods of manufacturing

A method of manufacturing a composite part, the method comprising:

• forming an initial radius filler on a composite panel, wherein the initial radius filler is formed from a plurality of plies of composite material stacked on the composite panel;
• forming a radius of curvature on at least one side of the initial radius filler;
• positioning a composite stiffener on the composite panel, wherein the composite stiffener is contoured to define a radius gap when joined with the composite panel;
• positioning the composite stiffener against the at least one side of the initial radius filler;
• compressing the composite panel and the composite stiffening member together via consolidation pressure;
• and
• heating the initial radius filler to at least one of a cure temperature, a melting temperature, or a fusing temperature to form, from the initial radius filler, a radius gap filler in the radius gap;
• wherein forming the initial radius filler includes forming the plurality of plies from continuous strips of composite material;
• wherein the continuous strips include unidirectional fibers oriented in the length dimension of the radius gap filler.

A method of manufacturing a composite part, the method comprising:

• determining an install location for at least one stiffener on a composite panel;
• forming an initial radius filler at the install location on the composite panel, wherein the initial radius filler is formed from a plurality of plies of composite material;
• positioning a composite stiffener on the composite panel, wherein the composite stiffener is contoured to define a radius gap when joined with the composite panel;
• using the initial radius filler to position the composite stiffener at the install location;
• compressing the composite panel and the composite stiffening member together via consolidation pressure;
• heating the initial radius filler to at least one of a cure temperature, a melting temperature, or a fusing temperature to form, from the initial radius filler, a radius gap filler in the radius gap;
• forming a radius of curvature on at least one side of the initial radius filler, wherein the composite stiffener is positioned against the at least one side of the initial radius filler
• wherein forming the radius of curvature includes size-reducing the at least one side of the initial radius filler to a pre-formed shape.