In cooperation between different EADS Business Units, a new advanced composite load introduction rib for high lift devices of future aircraft has been developed to minimize weight and manufacturing costs. The new integrated design of the laod introduction rib focuses on the reduction of the complexity and to simplify the Prefrom manufacturing. The complex loading of the load introduction structure requires a detailed numeric analysis for an accurate calculation of all critical stresses. The static analysis of the new composite load introduction rib and drive fittings show sufficient strength. Based on prior investigations, the composite lugs show satisfying damage tolerance behaviour leading to the conclusion that a second load path is not necessary. A new preform process chain with assembly stitching sub-preforms shows high manufacturing costs saving potential in comparison to current standard composite manufacturing. This is further enhanced by the application of a vacuum infusion process (VAP), outside the autoclave saving additional manufacturing costs. The influence of pre-form stitching, assembly and structural stitching, on the mechanical properties of the material is investigated in detail as well.
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