Composite assemblies are described that include composite spars that are co-cured with one or more sacrificial members on their flanges, forming an integrated sacrificial surface for the composite spars. In one embodiment, the composite assembly includes a composite spar having a web and flanges that project from sides of the web. The composite assembly further includes a sacrificial member of composite materials co-cured with the composite spar on an outer surface of at least one of the flanges. In addition, the sacrificial member has an outer surface that has been machined into conformance with an inner surface of at least one skin panel for an aircraft structure to form a contact surface with the at least one skin panel.

This relates to a composite structural element, in particular a rib or a spar, specifically for use in a torsion box of an aircraft structure such as a vertical tailplane, wherein the structural element defines a coordinate system with a first axis “a” wherein the structural element comprises a substantially planar main section defining a coordinate system with a first axis “a” extending along the longitudinal axis “L” of the structural element and a second axis “b” extending perpendicular to said longitudinal axis “L” within the planar main section and defining an angle of +90° with the first axis “a”, wherein the structural element contains a lay-up of single plies consisting of a fiber-reinforced composite material with a substantially unidirectional fiber orientation.

Embodiments are directed to systems and methods for two or more cured composite assemblies that are bonded together to form a tubular composite structure, wherein each of the cured composite assemblies do not have a tubular shape. The tubular composite structure may form a spar for an aerodynamic component, for example. The two or more cured composite assemblies may comprise carbon or fiberglass composite materials or a combination of materials. Each of the cured composite assemblies may further comprise axial edges that are configured to be bonded to another of the cured composite assemblies, wherein the axial edges have a sloped shape. An adhesive agent may be applied on the axial edges for bonding two cured composite assemblies. Alternatively, or additionally, one or more fasteners may be used to attach the axial edges of at least two cured composite assemblies.

A kit of parts for forming an aerofoil assembly is disclosed having a torsion box structure including a first attachment point and a second attachment point, the first and second attachment points being separated from each other along a separation axis, and a fixed leading or trailing edge structure including corresponding first and second attachment points, wherein a first structure includes a slidebly mounted abutment piece slideable along a slide path extending in a direction parallel to the separation axis and a fixing mechanism for fixing the slidebly mounted abutment piece. A second structure includes a corresponding abutment feature having a first abutment surface facing in a direction parallel to the separation axis of the second structure, such that, in use, the abutment piece prevents relative movement of the first and second structures.

An aerofoil shaped body includes a plurality of longitudinal spars, an upper aerofoil cover, and a lower aerofoil cover. The spars and the covers are made of composite laminate material. One of the spars is integrally formed with one of the covers to form a spar-cover such that the composite laminate material of the spar extends continuously into the cover through a fold region created between the spar and the cover. The fold region has a fold axis extending substantially in the longitudinal direction, and the fold axis projected onto two orthogonal planes has curvature in both those planes.

A composite wingbox structure formed of reinforced thermoplastic. The composite includes carbon fiber reinforcement and a plurality of insulation elements to localize the heat formed during the process of manufacturing the structure. The process of manufacturing the wingbox includes the steps of interleaving a series of insulations elements within a plurality of laminae and consolidating the insulation elements and laminae to form a laminate. The laminate is then aligned with a support structure such that the insulation elements overlie the supports structure. The laminate is then fused to the support structure using a non-contact heating process, such as inductive welding.

A winglet is disclosed including first and second covers, a front spar, a rear spar, a rib, and a mid spar between the front spar and the rear spar. The rib and each spar are joined to the first cover and to the second cover. The mid spar has a length and the mid spar curves along all or part of its length. The length of the mid spar extends from an inboard end of the mid spar to an outboard end of the mid spar, and the rib wraps around the inboard or outboard end of the mid spar.

An aircraft assembly is disclosed having a wing tip device connected to a wing tip of a wing by a first connector, a second connector, and a third connector. The wing tip device includes a front device spar and a rear device spar. The first connector is associated with the rear device spar. The second connector is spaced apart in a chordwise direction forward of the first connector, and the third connector is spaced apart in a chordwise direction rearward of the first connector. The third connector includes a spigot mounting formation.

A leading edge slat of a wing element of an aircraft. The aircraft defining a mark including a main fuselage axis x and a spanwise axis y. The wing procuring a lift along an axis z. The wing element having a skin forming the leading edge slat, a spar linked to the skin and a stiffening structure linked on the leading edge side to the spar and to the skin. The stiffening structure being formed from a formed sheet metal having a plurality of bosses distributed according to the length of the leading edge. The bosses extending between the spar and the inner face of the skin.

Aircraft landing gear forward trunnion support assemblies and related methods are described herein. An example aircraft wing disclosed herein includes a rear spar having a rear side and a front side opposite the rear side and a forward trunnion support assembly. The forward trunnion support assembly includes first and second vertical support fittings coupled to the rear side of the rear spar, and a trunnion housing with a bearing. The trunnion housing is coupled between the first and second vertical support fittings. A central axis of the bearing is perpendicular to the rear side of the rear spar. The forward trunnion support assembly also includes a side load fitting disposed on the rear side of the rear spar. A first end of the side load fitting is coupled to the second vertical support fitting, and a second end of the side load fitting is coupled to the rear spar.