Variable roller assembly and a method of controlling the variable roller assembly

A variable roller assembly for forming one or more radii along a composite material blank, the variable roller assembly comprising:

• a platform configured to support the composite material blank;
• a roller die configured to form the one or more radii along the composite material blank, wherein forming the one or more radii along the composite material blank forms a filler;
• a first actuator operably coupled to the roller die and configured to move the roller die in a linear direction along a y-axis;
• a second actuator operably coupled to the roller die and configured to move the roller die in a linear direction along a z-axis;
• and
• a controller in communication with the first actuator and the second actuator, wherein the controller is configured to:
• selectively activate the first actuator and/or the second actuator to variably move the roller die relative to the composite material blank, and
• maintain engagement of the roller die with the composite material blank to form the one or more radii along the composite material blank.