A method for manufacturing a rotor blade, including: a) arranging a first layup of fiber material inside a mold, the first layup corresponding to an airfoil of the rotor blade, b) arranging a second layup of fiber material on a core member before and/or after arranging the core member in the mold, the second layup including the core member corresponding to a web of the rotor blade, the core member comprising a recess configured to ensure a smooth transfer of loads into and out of the web, and c) curing a resin impregnating the fiber material of the first and second layup to form the rotor blade.

A method of repairing a composite structure or forming a component of a part is provided. The method includes releasably laying up of a first member that is curable at a first temperature at or above a constrained temperature limit of the composite structure or part, releasably laying up of a second member on the first member that is curable at a second temperature below the constrained temperature limit, curing the second member into a scaffold at the second temperature at the composite structure or part, transferring the first member and the scaffold remotely from the composite structure or part for first member curing and removing the cured first member from the scaffold for bonding of the cured first member to the composite structure or part.

Described are systems, methods, and apparatus for replacing the corrugated containers and dunnage to facilitate packaging of items in foam containers, referred to as polymer encapsulations, that can be used to protect and contain the item during shipment. When one or more items are ordered for delivery to a destination, the item(s) is picked from inventory and a rapidly setting polymer foam is injected around the bagged item to encapsulate and protect the item. For example, at packing, rather than placing the item in a corrugated container, temporary walls may be positioned around the bagged item and a pre-polymer injected into the space between the walls that surround the item such that a polymer forms that encases the item. After the polymer sets, the walls are retracted and the item is protected by the formed polymer encapsulation and available for transport to the destination.

A method of mounting, at a desired location, a vehicle sensor pad for a sensor system of a vehicle wherein the sensor pad is initially packaged in a product that includes a foldable clamshell-type housing folded to a closed position to contain the pre-formed sensor pad that was formed in situ therein when the housing was in an open position, prior to closing. The housing has an enclosed volume bounded by relatively thin and flexible walls, and outwardly extending tabs which facilitate opening. This structure enables the user to easily open the housing to remove the sensor pad, a cured silicone composition, by pushing inward on an outer surface of the outer wall of a base section of the housing. This product reduces the amount of manipulation needed to mount the sensor pad in a desired position, for example, during installation of a rain sensor system for a vehicle windshield.