Abstract In this paper, an imperfection detecting machine which has composite–aluminium hybrid beam structure with high-modulus carbon/epoxy composites in order to enhance dynamic stiffness and damping capacity of the structure is introduced. For the optimal design of the composite-aluminium hybrid beam structure, geometric shape of cross-section of aluminium beam, the stacking sequence and thickness of composite which is to be reinforced onto the aluminium beam are determined by considering the fundamental natural frequency and deformation of the structure under service conditions. The dynamic characteristics of the structure are analyzed by the finite element method, and the results show good agreement with the modal testing results. In addition, new designs of beam structure are also proposed for the next generation inspecting system which has much longer beam length. Parametric study for composite X -axis beam system and optimisation scheme of joint inserts are performed in the designing process.
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