A composite airfoil is disclosed. In various embodiments, a composite airfoil as disclosed herein includes an outer skin comprising one or more layers of carbon fiber composite material, the outer skin defining an aerodynamic surface having a leading edge; and a reinforcement material comprising a roll of fiberglass reinforced fabric positioned behind the outer skin along at least a portion of the leading edge.

In a first aspect, there is a method of making a rotor blade, including designing at least one of an upper skin, a lower skin, a support network, and components therefor; and forming at least one of the upper skin, the lower skin, a support network, and components therefor using an additive manufacturing process. In a second aspect, there is an airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

In one embodiment, a method may comprise coupling a plurality of reinforcement fibers to a plurality of spherical components; inserting the plurality of spherical components into an enclosure; and heating the enclosure to cause the plurality of spherical components to expand, wherein the plurality of spherical components expands to form a geodesic structure, wherein the geodesic structure comprises a plurality of polyhedron components configured in a geodesic arrangement.

A method of making a fan blade may include the steps of forming a core comprising fibrous material, and placing a first layer of dry fiber tows over the core using a robot. The first layer of dry fiber tows may be substantially un-crimped and may have a thermoplastic coating. A second layer of dry fiber tows may be placed over the first layer of dry fiber tows using the robot. The second layer may be un-crimped and coated similar to the first layer. The core, the first layer, and the second layer may be molded using resin transfer molding. The first layer may be placed over the core in a curved configuration. The core may include a three-dimensionally woven core formed on a loom and/or a plurality of layers of dry fiber tows placed by the robot.

A fibrous texture to form the fibrous reinforcement of a turbomachine blade made of composite material, the texture being made in one piece and having a three-dimensional weaving, and includes blade root, blade airfoil and blade support portions. The blade support portion includes a first area extending transversely from a first edge of the texture to form a leading edge and a second area extending transversely from the first area up to a second edge of the texture to form a trailing edge, the first area including warp yarns or strands made of second fibers different from the first fibers, the second fibers having an elongation at break greater than that of the first fibers, the first area having a first volume ratio in yarns or strands made of second fibers strictly greater than a second volume ratio in yarns or strands made of second fibers in the second area.

A composite manufacturing system has a tool having a substantially planar first portion and a substantially planar second portion, a first carriage configured to carry a first roller that is configured to selectively apply pressure to the first portion, a second carriage configured to carry a second roller that is configured to selectively apply pressure to the second portion, and the first carriage and the second carriage are movable relative to the tool.

A method is provided in one example embodiment and may include positioning at least one nozzle within a hollow portion of a rotor blade at a distance associated with a span of the rotor blade and providing, via the at least one nozzle, a liquid foam mixture in the hollow portion, wherein the liquid foam expands and becomes a solid foam material that fills the hollow portion of the rotor blade. Another method is provided in another example embodiment and may include providing a plurality of openings for a rotor blade that are positioned proximate to a hollow portion of the rotor blade and providing a liquid foam mixture in the hollow portion of the rotor blade through at least one opening of the rotor blade, wherein the liquid foam mixture expands and becomes a solid foam material that fills the hollow portion of the rotor blade.

In an aspect, a method of filling a plurality of cooling holes in an airfoil component, the method comprises injecting a curable composition into a fill channel such that the curable composition flows through the fill channel to the plurality of cooling holes; forming a plurality of beads of the curable composition on a surface of the component over the plurality of cooling holes; directing a radiation to the respective beads in directions parallel to the respective central axes of the cooling holes associated with the respective beads to cure curable composition of the respective beads; and heating the component to cure the curable composition located in the fill channel.

A bond assembly includes a fixture having a first section movably coupled to a second section. The first section and the second section are disposed opposite one another. A bladder assembly is mounted to at least one of the first section and the second section. The bladder assembly is configured to apply controlled, localized pressure and heat to a component receivable between the first section and the second section.

A resin fan includes a semi-molded article in which a first circular plate and blades are integrated. While the semi-molded article is retained, a composite mold is moved to a secondary molding side, a second mold is put in a first position and a third mold is moved to the first position and inserted into the first mold. An intermediate part extends over the inner surface-side of a large-bend part, and causes the end of the third mold to engage with the first mold. Next, resin is poured into a secondary forming mold, and a second circular plate is integrally molded continuous with the blades of the semi-molded article, and a fan is molded. Together with the opening of the second mold and the composite mold, the third mold and the composite mold are opened, each of the molds is moved to a second position.