Composite radius fillers, assemblies including composite radius fillers, and systems and methods of forming the same

A system comprising:

• a composite radius filler comprising a body having a longitudinal axis, wherein the body comprises:
• a main-portion that extends along the longitudinal axis and that has a first stiffness;
• and
• an end-portion that extends along the longitudinal axis, that is adjacent to the main-portion, that defines at least a portion of a terminal end of the body, and that has a second stiffness that differs from the first stiffness;
• wherein at least a first portion of an interface between the main-portion and the end-portion is at an angle relative to the longitudinal axis;
• and
• a tool comprising a first tool surface oriented at an angle corresponding to the angle of the interface relative to the longitudinal axis, and the first tool surface configured to engage a first main-portion surface of the main-portion, wherein the first main-portion surface forms part of the first portion of the interface.

A composite manufacturing method, comprising:

• changing a shape of at least a first main-portion surface of a main-portion of a composite radius filler by pressing a first tool surface of a tool into the first main-portion surface, wherein the composite radius filler comprises a body having a longitudinal axis, wherein the body comprises:
• the main-portion that extends along the longitudinal axis and that has a first stiffness;
• and
• an end-portion that extends along the longitudinal axis, that is adjacent to the main-portion, that defines at least a portion of a terminal end of the body, and that has a second stiffness that differs from the first stiffness;
• wherein at least a first portion of an interface between the main-portion and the end-portion is at an angle relative to the longitudinal axis, and wherein the first main-portion surface forms part of the first portion of the interface;
• wherein the first tool surface is oriented at an angle corresponding to the angle of the interface relative to the longitudinal axis.