A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

In accordance with at least one aspect of this disclosure, a composite structure can be formed of or including a plurality of composite strips. The plurality of composite strips include one or more filler strips which can have at least one filler edge having a filler edge geometry between a first surface and second surface, the second surface being opposite the first surface. The filler edge geometry can be configured to prevent formation of one or more gaps between one or more adjacent composite strips.

Compaction systems and methods of compacting components are provided. In one aspect, a laminate of a component can be laid up on a tool of a compaction system. The laminate defines a cavity. A noodle is positioned relative to or in the cavity. A noodle ring is then positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. A plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity.

In accordance with at least one aspect of this disclosure, a composite structure can be formed of or including a plurality of composite strips. The plurality of composite strips include one or more filler strips which can have at least one filler edge having a filler edge geometry between a first surface and second surface, the second surface being opposite the first surface. The filler edge geometry can be configured to prevent formation of one or more gaps between one or more adjacent composite strips.

The number of composite material layers laminated to realize a preset thickness of a substrate, for example, a web portion of a panel structural body is referred to as a reference lamination number. Doubler layers that are the composite material layers added to the reference lamination number are laminated in at least a rib base bottom portion of the substrate. Reinforced fibers that includes basic layers and the doubler layers reach a tip portion of the rib. Filler layers that are composite material layers located only at a portion corresponding to a filler region may be laminated in the rib base bottom portion in addition to the doubler layers.

A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.

Systems and methods for curing complex fiber-reinforced composite structures utilize two distinct heat sources. A first heat source is utilized for heating a complex fiber-reinforced composite structure from within an internal portion of the complex fiber-reinforced composite structure. A second heat source is utilized for heating the complex fiber-reinforced composite structure from an external surface of the complex fiber-reinforced composite structure.

Compaction systems and methods of compacting components are provided. In one aspect, a laminate of a component can be laid up on a tool of a compaction system. The laminate defines a cavity. A noodle is positioned relative to or in the cavity. A noodle ring is then positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. A plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity.

A method of constructing a composite, radius filler noodle for a co-cured spar or stringer used in aircraft construction includes forming a core of the noodle from unidirectional pre-preg tape and stacking pluralities of pre-prep fabric strips in layers surrounding the core.

A die assembly for forming a composite gap filler, including a first die having a first portion which extends along a first central axis of the first die and has a first curved surface which has a radius which changes as the first curved surface extends about the first central axis. A second die a second portion which extends along a second central axis of the second die and has a second curved surface which has a radius which changes as the second curved surface extends about the second central axis. A third die defines a third wall member which extends about the third die and which changes in width dimension wherein with the first die abutting the second die and with the third wall member abutting the first and second dies, a closed gap is formed.