Ouch!
If it's any consolation, I know the feeling. My first carbon leading edge skin for one wing came out of the mold and looked perfect... except along the apex of the leading edge itself where there was significant bridging... resulting in it ending up in the bin. One of the layers in my infusion stack (possibly the peelply or the vacuum bag itself) was constained in some way and prevented the vac-bag from pressing into the apex of the curve. The same thing happened on my first attempt to infuse the tail fin leading edge, despite my earlier experience and best efforts. Expensive!!
Following those two screw-ups I modified the way I assembled the infusion stack and achieved perfection
A material's maximum compressive strength can only be achieved if it can be prevented from buckling. Maintaining stiffness is the other side of the equasion. I was amazed at the difference in stiffness between the various grades of carbon cloth when I was making test samples for my leading edges and spars. Two different types of carbon cloth performed totally differently to each other. One was a 200gsm, non-woven, bi-axial cloth with a low modulous and the other was a 195gsm twill weave with a medium to high modulous. The bi-axial (which I expected to perform better) was very bendy and totally unsuitable, while the medium-high modulous twill cloth was at least 5-10 times stiffer (my subjective measure.) While the bi-axial may have been fine for use in my spars, it would have been useless in the leading edges. For simplicity I used the twill cloth throughout my build.
I see the spar cap under compression buckled and failed between two ribs, as might be expected. How did you stiffen your spar (caps/web) when you repaired the damage?
Stiffness can be dramatically improved by adding 'thickness' to a part without adding significant weight. In my case, all my spars are fabricated using just two layers of 195gsm twill cloth (cut at +/-45deg) and are very light and bendy. They are stiffened by the fore and aft ribs bonded to the shear web and between each pair of ribs by a strip of light weight foam board (25mm wide x 5mm thick) are laminated between the two layers of cloth. This significantly stiffens the shear web without adding much weight. The spar caps are stiffened both by the carbon rods that are encapsulated between the two layers of cloth and further by the leading edge, where it is bonded to the spar caps, lending horizontal and torsional stiffness.
Thanks for sharing your results - failures are every bit as important as successes, 'cos that's where we learn!
Keep going - you'll get there!
Phil.