Due to its high load-carrying efficiency, multi-step bonded joints are widely used in composite joints and repairs.A new multi-step manufacturing process was introduced, with which a sharp comer could be generated to avoid the resin-rich area.The damage initiation and propagation under low velocity impact was analyzed by finite element method using progressive damage and inter-ply fracture criterion.Compression residual strength was also calculated.Fine agreement between the analysis and test results was achieved.