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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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