In the design of a patch for a small hole on metal stressed skin, what should be the major consideration?

When designing a patch for a small hole on metal stressed skin, the major consideration should be the shear strength of the riveted joint. This is critical because the patch needs to effectively restore the structural integrity of the stressed skin, ensuring it can withstand the loads and stresses it will encounter during operation. The riveted joint's shear strength is essential in maintaining the connection between the patch and the existing structure, as a weak joint can lead to failure under stress, compromising the safety and performance of the aircraft.

In this context, while the weight of the patch, cost of materials, and appearance of the patch are relevant factors in the overall design process, they do not take precedence over ensuring that the patch is securely and effectively joined to the stressed skin. The focus on shear strength ensures that the repaired area can handle the aircraft's operational loads, making it the most crucial consideration in the design process.