Abstract: A composite radius filler include a base portion and a tip portion. The base portion is formed of composite plies varying in overall width along an overall lengthwise direction and defining a variable cross-sectional shape of the base portion along the lengthwise direction. The base portion includes at least one transition zone having a transition start and a transition end along the lengthwise direction. The composite plies of the base portion are arranged in one or more stacks each stack having a predetermined fiber orientation angle sequence and a stack width that changes within the transition zone. The tip portion includes a plurality of composite plies formed into a generally triangular cross-sectional shape and stacked on top of the base portion.

Abstract: A composite radius filler include a base portion and a tip portion. The base portion is formed of composite plies varying in overall width along an overall lengthwise direction and defining a variable cross-sectional shape of the base portion along the lengthwise direction. The base portion includes at least one transition zone having a transition start and a transition end along the lengthwise direction. The composite plies of the base portion are arranged in one or more stacks each stack having a predetermined fiber orientation angle sequence and a stack width that changes within the transition zone. The tip portion includes a plurality of composite plies formed into a generally triangular cross-sectional shape and stacked on top of the base portion.

Abstract: A pressure bulkhead for a pressurized vehicle such as an aircraft employs a plurality of layers of composite fiber material having uni-directional fibers arranged in a single direction within the composite fiber material. The pressure bulkhead incorporates non-traditional radial and circumferential stiffening members into a composite laminate and aligns the radial stiffening members with the direction of dominant load paths. The radial and circumferential stiffening members are interlaid between full layers of the composite fiber material. Related methods of manufacturing the pressure bulkhead include using automated fiber placement equipment to form each layer of the pressure bulkhead and discretely orient the integral stiffeners and the uni-directional fibers in each layer.