Abstract: Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.

Abstract: A method of inspecting a secondary bond of a laminated part includes positioning the laminated part within a sealed chamber. The method also includes reducing a pressure within the sealed chamber to below a pressure outside the sealed chamber when the laminated part is positioned within the sealed chamber. The method further includes, when the pressure within the sealed chamber is reduced to below the pressure outside the sealed chamber, measuring a gradient of change of a surface profile of the laminated part. The method additionally includes determining a condition of the secondary bond based on the gradient of change of the surface profile of the laminated part.

Abstract: Disclosed herein is a method of inspecting a secondary bond of a laminated part. The method comprises positioning the laminated part within a sealed chamber. The method also comprises reducing a pressure within the sealed chamber to below a pressure outside the sealed chamber when the laminated part is positioned within the sealed chamber. The method further comprises, when the pressure within the sealed chamber is reduced to below the pressure outside the sealed chamber, measuring a gradient of change of a surface profile of the laminated part. The method additionally comprises determining a condition of the secondary bond based on the gradient of change of the surface profile of the laminated part.

Abstract: A blade stringer for a composite panel having an inside surface includes a proximal section, comprising a web attached to and extending approximately perpendicularly from the inside surface of the panel, and a free distal end. The web has a thickness and a height, and includes a plurality of continuous composite plies. The free distal end has a plurality of local plies interleaved and co-cured with the continuous plies, the distal end defining a bulb having a thickness that is greater than the web thickness and less than about a third of the web height.