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There are significantly different manufacturing processes and part
counts associated with composites that are not currently addressed
within the procurement and life cycle management processes in the
Department of Defense (DoD). A series of initiatives have
culminated in significant evidence over the last decade to combat
the implied risk of composite aircraft. An Air Force Research Labs
program, Advanced Composite Cargo Aircraft (ACCA), provides
substantial support for the impact of part size on life cycle cost
on payload aircraft. This paper evaluates select current methods
used and seeks to introduce modifications to the projected
manufacturing hours cost. The findings suggest the impact of
monolithic parts appears to permeate most of the major cost
categories in development and production.
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