Abstract: The paper seeks to address the techniques of structural design, technological design, product manufacturing and mechanical properties of the wing with given shape and size. By using finite element analysis software, the static analysis of composite wing was carried out, the main bearing structure was extracted, and the internal skeleton structure was designed. A structural scheme of "I-beam+thin skin+variable thickness" was put forward. Through the design of carbon fiber composite material and polymethacryl imide (PMI) foam, the structure of the wing was realized. The design idea of die for complex shape parts was studied, and the central wing box and wing die were designed. The process flow of wing forming was designed by molding process and co-bonding. Through this method, the wing was manufactured successfully and the mechanical properties were tested. Finally, the surface quality and shape size of the prepared wing meet the requirements, and the design and manufacture of the wing with light weight and heavy load ratio are realized. The rationality and validity of the structure design and forming method are proved.   

Key words: ultra-light composite wing, strength analysis, structural design, process flow, load/mass ratio