This study discusses not only failure mechanisms and predictions of metal and composite bonded joints using both strength of materials and fracture mechanics methods, but also the analysis, design and manufacturing of stitched joints using Resin Transfer Moulding and Resin Film Infusion. These techniques have great potential in the manufacturing of lightweight composite structures. The damage tolerance of structural bonded joints is comprehensively covered and when dealing with optimum design the latest Evolutionary Structural Optimization technology is used to develop optimal joint design with improved strength. Joining design is critical in a structural design process, particularly for weight-sensitive structures, and bonded joints are being increasingly utilized, particularly in the aeronautical, automotive, civil and maritime industries.