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Each wing has two I-section spars. The front spar on one side is the same as the rear spar on the opposite side. Many layers of uni-directional carbon fiber make the spar caps. The number of layers in the spar caps decreases from root to tip. Each spar has a shear web. The shear web has GFRP skins and a rigid foam core. Glass cloth fillets attach the spar caps to the shear web.
A rear web closes the trailing edge of the wing. An end rib closes the outboard end of the wing. A removable GFRP tip attaches to the wing shells and outer rib with screws.
The flaps and ailerons have top and bottom shells. Each shell has mixture of CFRP and GFRP cloth. The shells have rigid foam cores and bond together.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The horizontal stabilizer has a front spar and a rear spar. Three pairs of ribs give strength to the center area. The elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core.
The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The shells bond together at a flange.
The canopy is a CFRP molding with inner and outer frames which bond together. The canopy has a large one-piece acrylic glass window. The passenger door is a CFRP molding with inner and outer frames. The frames bond together. The door has an acrylic glass window.
A polyurethane paint finish protects the outside skin of the airplane from ultraviolet rays and humidity.
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2. Types of Structure
The DA 40 is constructed from 2 main types of composite structure.
A. Glass Fiber Reinforced Plastic (GFRP)
GFRP is very thin glass fibers bonded together by resin. The glass fibers give most of the strength and the resin maintains the shape. The resin also bonds to other structural components such as metal attachment brackets or metal bushings.
The glass fibers are woven to make glass cloth. The orientation and weave of the glass in the cloth affects the structural strength of the cloth. A component can have many layers of cloth bonded together with resin. This is called lamination.
GFRP has very good properties. It is strong and flexible. It is very resistant to chemical attack and very little maintenance is necessary.
B. Carbon Fiber Reinforced Plastic (CFRP)
CFRP is very thin carbon fibers bonded together by resin. The carbon gives most of the strength and the resin maintains the shape. The resin also bonds to other structural components such as metal attachment brackets or metal bushings.
CFRP is very similar to GFRP. The main advantage of CFRP is that it is stronger and more rigid than GFRP.
3. Laminated Components
A laminated component has 2 or more layers of glass/carbon cloth. The direction of the fibers in the cloth give the properties for each layer. Extra layers are bonded to areas to give more strength.
4. Sandwich Structure
Many of the components in the DA 40 have a sandwich of 2 skins and a core. GFRP or CFRP make the skins and rigid plastic foam makes the core.
The skins must bond to the core of a sandwich structure completely. If the skins do not bond to the core the component can fail.
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Structures

5. Bonded Components
A number of components can bond together to make a larger component. Special thick resin bonds these components together and fills the gap in a joint.
6. Repair Limitations
Repairs which are categorized as 'Class 1' in accordance with Section 51-10, Paragraph 2, may only be carried out in accordance with a repair scheme which has been approved by the manufacturer. Such repairs are not described in this Airplane Maintenance Manual.
Doc # 6.02.01 Page 3
Rev. 4 09 Jan 2003

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