The fabrication cost of composite aircraft structures is revisited and the effect of part size on cost is examined with emphasis on design decisions which affect the ease of (bonded) repair and the total cost of the part and subsequent repairs. The case of moderately loaded stiffened fuselage or wing panels under compression is analysed in detail and the fabrication cost of the panel made as a single piece or as an assembly of smaller identical components or modules is determined. The cost of special purpose repairs for two different damage sizes is compared to removing and replacing damaged modules. Hand layup and automated processing are compared. It is found that for certain repair sizes removing and replacing modules leads to lower overall cost as compared to applying a special purpose repair.