Wing spar is the major load-carrying structure with large dimension and complex stress. Composite wing spar features weight reduction, load-carrying increase and long service life. To achieve the effective load carrying and transfer, and satisfy process coordination, composite wing spars are required to have accurate lay-up position and angle, and strictly controlled profile tolerance. However, due to complex lay-up and various sections of large composite wing spar, the traditional manual process of large composite components frequently brings about quality issues in the internal and unstable quality, which requires higher level of manufacturing process so as to satisfy engineering requirements. The digital technology adopted from design to manufacturing, and the automatic lay-up, cutting and forming of materials will contribute to the high quality forming of composite wing spar so as to satisfy all engineering requirements.