This paper is intended to present a comprehensive approach including the design of a cyber-physical system (CPS) for structural health monitoring (SHM) of composite aircraft structures. The paper summarises the developments of a miniaturised data acquisition (DAQ) unit. Afterwards, the existing Wireless Sensor Networks (WSNs) based SHM technologies are presented and compared to develop a new approach. This new approach is the CPS for SHM consisting of a miniaturised on-board DAQ, WSN and a user-friendly graphical user interface (GUI). The cyber and physical parts of the CPS are separately covered in detail. To manage the entire system, a concept is addressed to define all the stages and components of how to work together during the monitoring of structural integrity. This concept involves data acquisition, the transmission of sensing results wirelessly, data visualisation and processing using a developed software with GUI. The proposed CPS for SHM shows that it is a promising and time-efficient system for multi-stage and multi-disciplinary SHM applications. This approach does not require other software tools such as LabView and Matlab to visualise and process sensor data. All systems are integrated into one platform with this concept. Another advantage is that the proposed system is flexible to be improved by adding new features to the software developed in the cyber part of the CPS. Additionally, the CPS is convenient for on-board aircraft SHM applications with a wireless miniaturised DAQ unit powered by the software with GUI.

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