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A method of forming a composite article may include initially curing a composite laminate at an initial temperature to an initial cure stage of 30-50 percent of full cure and beyond a gel point to form an initially-cured composite laminate. The method may initially include heating the initially-cure

A method of forming a composite article may include initially curing a composite laminate at an initial temperature to an initial cure stage of 30-50 percent of full cure and beyond a gel point to form an initially-cured composite laminate. The method may initially include heating the initially-cured composite laminate to an intermediate temperature higher than the initial temperature and above a resin glass transition temperature. In addition, the method may include intermediately curing the composite laminate to an intermediate cure stage of 50-70 percent of full cure while on a final forming tool to form an intermediately-cured composite laminate. Furthermore, the method may include removing the intermediately-cured composite laminate from the final forming tool, and finally curing the intermediately-cured composite laminate at a final temperature higher than the intermediate temperature to a final cure stage.

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1. A method of forming a composite article, comprising: initially curing a composite laminate at an initial temperature to an initial cure stage of 30-50 percent of full cure and beyond a gel point to form an initially-cured composite laminate;heating the initially-cured composite laminate to an int

1. A method of forming a composite article, comprising: initially curing a composite laminate at an initial temperature to an initial cure stage of 30-50 percent of full cure and beyond a gel point to form an initially-cured composite laminate;heating the initially-cured composite laminate to an intermediate temperature higher than the initial temperature and above a resin glass transition temperature;intermediately curing the composite laminate to an intermediate cure stage of 50-70 percent of full cure while on a final forming tool to form an intermediately-cured composite laminate;removing the intermediately-cured composite laminate from the final forming tool; andfinally curing the intermediately-cured composite laminate at a final temperature higher than the intermediate temperature to a final cure stage. 2. The method of claim 1, further including the step of: laying up the composite laminate on a flat initial forming tool prior to initially curing the composite laminate. 3. The method of claim 1, further including the step of: laying up multiple plies of thermoset prepreg to form the composite laminate prior to initially curing the composite laminate. 4. The method of claim 1, further including the step of: laying up multiple plies of dry fiber; andinfusing the plies with resin to form the composite laminate prior to initially curing the composite laminate. 5. The method of claim 1, further including the step of: consolidating the composite laminate prior to and/or during the initially curing of the composite laminate. 6. The method of claim 5, wherein the step of consolidating includes: consolidating the composite laminate with vacuum pressure applied by a bagging assembly. 7. The method of claim 1, further including the step of: trimming the initially-cured composite laminate into a perimeter shape prior to intermediately curing the composite laminate. 8. The method of claim 1, wherein the step of heating the initially-cured composite laminate to the intermediate temperature comprises: heating the initially-cured composite laminate to at least approximately 20 degrees F. above the resin glass transition temperature. 9. The method of claim 1, wherein the step of initially curing the composite laminate comprises: initially curing the composite laminate to approximately 40 percent of full cure. 10. The method of claim 1, wherein the step of intermediately curing the composite laminate comprises: intermediately curing the composite laminate to 60 percent of full cure. 11. A method of reworking an existing composite structure, comprising: heating a thermoset composite laminate to an initial temperature for an initial dwell time period;initially curing the composite laminate at the initial temperature to an initial cure stage of 30-50 percent of full cure and beyond a gel point to form an initially-cured composite laminate;heating the initially-cured composite laminate to a temperature higher than the initial temperature and above a resin glass transition temperature;forming the initially-cured composite laminate at the higher temperature to a contour of an existing composite structure; andfinally curing the composite laminate at the higher temperature to a final cure stage with the composite laminate conformed and joined to the contour of the existing composite structure. 12. The method of claim 11, wherein the step of heating the composite laminate to the temperature higher than the initial temperature and finally curing the composite laminate includes: heating the composite laminate to an intermediate temperature and holding for an intermediate dwell time during forming of the composite laminate to the contour; anddirectly ramping from the intermediate temperature to a final temperature above the intermediate temperature to finally cure the composite laminate. 13. The method of claim 11, further including the step of: consolidating the composite laminate prior to and/or during the initially curing of the composite laminate. 14. The method of claim 13, wherein the step of consolidating includes: consolidating the composite laminate with vacuum pressure applied by a bagging assembly. 15. The method of claim 11, wherein the step of initially curing the composite laminate comprises: initially curing the composite laminate to approximately 40 percent of full cure. 16. The method of claim 11, further including the step of: trimming the initially-cured composite laminate into a perimeter shape to form a patch complementary to a rework area of the existing composite structure. 17. The method of claim 16, wherein the step of trimming the initially-cured composite laminate into a patch includes: machining an edge treatment onto a perimeter edge of the patch to match a scarf angle formed in the rework area of the existing composite structure. 18. The method of claim 11, wherein the step of heating the initially-cured composite laminate comprises: heating the initially-cured composite laminate to at least approximately 20 degrees F. above the resin glass transition temperature. 19. The method of claim 11, further including the step of: laying up multiple plies of thermoset prepreg to form the composite laminate prior to initially curing the composite laminate. 20. A method of reworking an existing composite structure, comprising: heating a composite laminate to an initial temperature;initially curing the composite laminate at the initial temperature to an initial cure stage of 30-50 percent of full cure and beyond a gel point to form an initially-cured composite laminate;heating the composite laminate to an intermediate temperature and holding for an intermediate dwell time while forming to a contour of the existing composite structure;ramping up the temperature of the composite laminate from the intermediate temperature to a final temperature above the intermediate temperature and holding for a final dwell time; andfinally curing the composite laminate at the final temperature to a final cure stage while bonding to the existing composite structure during the final dwell time.