Abstract: A composite material elongate structural member, such as a spar, for use in an aerospace structure, comprises a web disposed between upper and lower flanges. The web may include a clockwise twist about an axis parallel to the length L at a first portion towards the wing-root-end of the spar and a counter-twist in the anticlockwise direction at a second portion towards the wing-tip-end of the spar. The geometry of the spar may vary non-linearly along its length (L) so that the developed width of the spar as measured from a distal edge of the upper flange via the web to a distal edge of the lower flange varies linearly with increasing distance along the length (L). The risk of causing, during fabrication of the spar, undesirable creasing, stressing or stretching of composite material layers in a region in which the geometry of the member varies non-linearly may be reduced by means of such an arrangement.

Abstract: A method for making a rib for an aerofoil structure, the aerofoil structure including a skin component, the method including the steps of scanning the inner surface of the skin component to determine the surface profile thereof, providing a rib having a rib body and a rib foot protruding from the body, machining a foot surface profile into the rib foot, the foot surface profile being arranged to complement the skin inner surface profile where the rib foot is intended to abut the skin component.

Abstract: A method of making a shim comprises the steps of providing a first structural component, such as a rib foot of an aircraft wing. The rib foot is then scanned or mapped to generate the surface profile of the rib foot. The shim is then formed to include a feature on its surface which complements the surface profile of the assembly surface.

Abstract: A method of forming a piece from a composite material is disclosed in which a mandrel is used that reduces relative movement between the mandrel and the piece during the curing process.

Abstract: An aerofoil structure comprises first and second opposed skin components which are joined together and spaced apart by a pair of opposed spar components. The skin components have respective outer and inner surface profiles. The skin and spar components define a space envelope and a rib is arranged within the space envelope. The rib comprises a rib body and a series of rib feet. The rib feet comprise a leg and a rib foot plate. The rib foot plate is dimensioned, positioned and angled so as to conform to the inner surface profile of the skin component against which it is intended to be arranged.

Abstract: A composite material elongate structural member, such as a spar, for use in an aerospace structure, comprises a web disposed between upper and lower flanges. The web may include a clockwise twist about an axis parallel to the length L at a first portion towards the wing-root-end of the spar and a counter-twist in the anticlockwise direction at a second portion towards the wing-tip-end of the spar. The geometry of the spar may vary non-linearly along its length (L) so that the developed width of the spar as measured from a distal edge of the upper flange via the web to a distal edge of the lower flange varies linearly with increasing distance along the length (L). The risk of causing, during fabrication of the spar, undesirable creasing, stressing or stretching of composite material layers in a region in which the geometry of the member varies non-linearly may be reduced by means of such an arrangement.

Abstract: A method of making a shim comprises the steps of providing a first structural component, such as a rib foot of an aircraft wing. The rib foot is then scanned or mapped to generate the surface profile of the rib foot. The shim is then formed to include a feature on its surface which complements the surface profile of the assembly surface.

Abstract: A method of forming a piece from a composite material is disclosed in which a mandrel is used that reduces relative movement between the mandrel and the piece during the curing process.