Abstract: A composite bonded repair method for an aircraft is provided. The method includes generating a doubling patch of a portion of the aircraft from topographic data, filling damage at the portion of the aircraft with filler material, applying adhesive to the portion of the aircraft and the filler material and adhering the doubling patch to the adhesive.

Abstract: An access door assembly includes a door panel located at a door opening and a primary hinge having a primary hinge axis and operably connected to the door panel. A guide track is affixed at the door opening and is operably connected to the door panel to guide rotation of the door panel about the first hinge axis. A secondary hinge having a secondary hinge axis is operably connected to the door panel. The secondary hinge allows for rotation of a first portion of the door panel about the secondary hinge axis, while a second portion of the door panel is stationary.

Abstract: An access door assembly includes a door panel located at a door opening and a primary hinge having a primary hinge axis and operably connected to the door panel. A guide track is affixed at the door opening and is operably connected to the door panel to guide rotation of the door panel about the first hinge axis. A secondary hinge having a secondary hinge axis is operably connected to the door panel. The secondary hinge allows for rotation of a first portion of the door panel about the secondary hinge axis, while a second portion of the door panel is stationary.

Abstract: A composite bonded repair method for an aircraft is provided. The method includes generating a doubling patch of a portion of the aircraft from topographic data, filling damage at the portion of the aircraft with filler material, applying adhesive to the portion of the aircraft and the filler material and adhering the doubling patch to the adhesive.

Abstract: A method of integrally forming at least one stiffener onto a sheet metal component configured to carry a load is provided including generating a stereolithography file. The stereolithography file includes a surface geometry of the at least one stiffener extending from a surface of the sheet-metal component. The surface geometry of the stereolithography file is sliced into a plurality of thin strips. The plurality of thin strips is substantially parallel to the surface of the sheet metal component. Energy from an energy source is applied to a powdered material such that the powdered material fuses to form the plurality of thin strips. One of the plurality of thin strips is integrally formed with the surface of the sheet-metal component. Each of the plurality of thin strips is integrally formed with an adjacent thin strip to create at least one stiffener.