A method for forming complexly shaped composite laminate assemblies. A
pair of dry fiber preforms are placed on a tool with a thin film adhesive
layer therebetween. A vacuum bag encloses the preforms and the adhesive
layer. The preforms are heated to a temperature sufficient to cause the
adhesive to become viscous and to wet several plys of each of the
preforms. The preforms are then allowed to cool slightly before resin is
infused via a vacuum source through each of the preforms to thoroughly
wet each of the preforms. The resulting joint formed at the bond line of
the two preforms is stronger than what would be formed simply by adhering
two otherwise completely formed preforms together because the dry fiber
preforms, in connection with the heating of the preforms, allow wetting
of several plys of each of the preforms at the joint area, rather than
just the surface ply of each preform.