Recycled Resin Infusion Radius Filler and Method

A method for forming a tailorable composite material longitudinal radius filler, the method comprising:

• harvesting an amount of a waste dry fiber material from a separate composite material formation process;
• forming a recycled dry fiber material from the waste dry fiber material:
• tooling the recycled dry fiber material to form the tailorable composite material longitudinal radius filler;
• impregnating the recycled dry fiber material with a resin-containing material to form a curable composite material longitudinal radius filler;
• and
• curing the curable composite material longitudinal radius filler to form a cured composite material longitudinal radius filler configured to comprise a selected stiffness.

A method of making a composite material assembly comprising a composite material longitudinal radius filler, the method comprising:

• providing at least one composite material assembly member, said at least one composite material assembly member comprising a composite material assembly member first side and a composite material assembly member second side, said composite material assembly member further comprising a longitudinal radius filler cavity bounded by the composite material assembly member second side, said longitudinal radius filler cavity comprising a longitudinal cavity radius, said at least one composite material assembly member comprising a first stiffness value, said composite material assembly member comprising a dry fiber material impregnated with a resin-containing material to form the composite material assembly member;
• positioning a tailorable composite material longitudinal radius filler in the longitudinal radius filler cavity to form the composite material assembly, said tailorable composite material longitudinal radius filler comprising a recycled dry fiber material impregnated with a resin-containing material to form the tailorable composite material longitudinal cavity filler, said tailorable composite material longitudinal radius filler comprising a radius filler longitudinal radius configured to substantially match the longitudinal cavity radius, said tailorable composite material longitudinal radius filler configured to completely fill the longitudinal radius filler cavity, said tailorable composite material longitudinal radius filler comprising a second stiffness value;
• forming the composite material assembly;
• wherein the recycled dry fiber material comprises a tailored form of the dry fiber material;
• and
• wherein a stiffness ratio of the first stiffness value to the second stiffness value is a stiffness ratio ranging from about 1:6 to about 6:1.