Although the deployment of carbon fibre structural components has enjoyed wide success on smaller aircraft, their acceptance on larger transport airframes is less sanguine – especially in the case of primary structure applications where the increasing out of plane loads found on the larger airframes have exposed the weak interlaminar properties of the layered material system. This has led to an overreliance on mechanical attachments to suppress these through thickness failures, which ultimately degrades structural performance and increases manufacturing costs. Until these resin dominated failure modes can be dealt with more effectively, without adversely affecting the in plane properties of the laminate, the true weight-savings potential afforded by carbon fibre material systems will be difficult to attain. This paper describes how researchers at NASA-LaRC and The Boeing Company are working to develop a next generation stitched composite design solution that addresses the fundamental challenges in achieving improved structural performance and reduced fabrication costs for large carbon fibre airframe structures.