Composites have revolutionized aircraft design, offering high strength with light weight—but at a cost. The material itself is made as the part is produced, and many factors influence its performance, so the testing required is complex and time-consuming. Certification of Boeing’s 787, with its carbon-fiber wing and fuselage, required tens of thousands of tests, from material coupons to complete structures, adding to the development time and cost. To reduce the development and ...

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