Structural Assessment of a Carbon Fibre Composite Wing Assembly

A lightweight aerodynamic wing assembly incorporating carbon fibre composite skins with aluminium ribs and spars was under development, requiring detailed structural assessment to validate its performance under representative aerodynamic loading conditions. The hybrid construction demanded careful evaluation of load transfer between composite and metallic components to ensure structural integrity and reliable operation.

Finite element analysis was employed to assess the structural behaviour of the complete assembly, validate the load-carrying capability of the wing, and support design development prior to manufacture.

Challenge

Hybrid composite structures present unique engineering challenges due to the interaction between materials with significantly different stiffness characteristics. Ensuring efficient load transfer between the carbon fibre skins, aluminium ribs, and spars is essential for achieving the required strength, stiffness, and structural reliability while maintaining a lightweight design.

The objective was to:

• Evaluate the structural response of the complete wing assembly

• Assess load transfer between the composite skins and aluminium internal structure

• Identify critical stress concentrations and deformation behaviour

• Validate the structural integrity of the wing under aerodynamic loading

• Provide engineering insight to support design refinement and optimisation

Solution

A detailed finite element model of the complete wing assembly was developed, incorporating the composite skins together with the aluminium ribs and spars. Representative aerodynamic loading conditions were applied to evaluate the structural performance of the assembly and investigate the interaction between the different structural elements.

The analysis:

• Simulated aerodynamic loading representative of operational conditions

• Evaluated stress distribution throughout the composite and metallic components

• Assessed deformation and structural stiffness of the wing assembly

• Investigated load transfer between skins, ribs, and spars

• Identified critical structural regions requiring further assessment or refinement

• Provided engineering recommendations to support design validation

The results provided a comprehensive understanding of the wing's structural behaviour, enabling informed engineering decisions before prototype manufacture and physical testing.

Outcome

The study delivered a validated engineering assessment of the wing assembly and supported key design decisions by:

• Confirming the structural performance of the hybrid composite design

• Validating load transfer between composite and aluminium components

• Identifying critical stress regions and deformation characteristics

• Supporting weight-efficient structural optimisation

• Reducing development risk and minimising the need for costly design iterations and prototype testing

Testimonial

“The structural assessment gave us confidence in the performance of our composite wing design and provided valuable insight into the interaction between the carbon fibre skins and aluminium support structure. The analysis helped validate our design decisions before manufacture and reduced development risk..”​

— Composite Structures Engineer