A single piece co-cured composite wing is disclosed. The wing has a flying
surface and structural members. In one embodiment the structural members
may be a plurality of spars. The spars may have various shapes to
increase the buckling strength. The spars may be wave shaped, such as a
sinusoidal shape. The flying surface and the structural members are
co-cured in order to form a single piece, integral wing structure. A
process for manufacturing a single piece co-cured wing is also disclosed.
The process may include laying out composite sheets for the flying
surface of the wing. Then, the composite material of the spars is
arranged around a plurality of pressurizable forms. Finally, the
composite material is cured in a clamshell frame. A single piece co-cured
composite structure is also disclosed that includes an outer skin, and
inner skin, a frame, and a stringer.