COMPOSITE ARTICLE AND METHODS THEREFOR

A method is provided for forming a composite article to have a primary composite structure and an integral secondary composite structure that extends out of a plane defined by the primary composite structure. The method includes laying-up first plies to construct the primary composite structure. The first plies contain continuous reinforcement material and extend from a first zone that will define the primary composite structure into a second zone that will define the secondary composite structure. During laying-up of the first plies, additional plies are interleaved with the first plies within the second zone but not the first zone. The additional plies originate within a build-up zone between the first and second zones and extend therefrom into the second zone. After interleaving the plies, the build-up zone is deformed to orient the second zone and form the secondary composite structure that extends out of the plane defined by the continuous reinforcement material of the first plies.