Yep djcross is cent percent right , beyond a certain threshold you cant replace the metallic structure with composites , it would be nothing short ,than going back to the drawing board and designing a new aircraft.
If they managed it to reach any where to 15 % then its pretty good
says who ? I know for a fact that designing a new aircraft is not necessary for simple things like panels. you may have to do a lot more analysis to change the main structures (like ribs or the stringers) but even that can be done. take the B-747-8 for instance. there is whole lot of composites used, but although major design work is required, its not akin to redesigning the entire aircraft itself.
testing would generally involve replacing a few metallic ribs with composite ribs and then after a period of time it would be inspected to gather data- after which it can be used for other ribs as well. At least thats the way its planned for the B-787. later iterations will start getting composite ribs in larger nos. after the first few give adequate data on their usage.
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