Embodiments are directed to systems and methods for manufacturing composite assemblies comprising laying up composite plies on molds for two or more uncured components, joining the molds for the two or more uncured components to form a tubular body, and curing the joined components simultaneously to create a single composite assembly. The single composite assembly may form a spar for an aerodynamic component. The method may further comprise forming at least one axial edge having a sloped shape on the uncured components and mating the sloped axial edges together when joining the uncured components. The molds for the two or more uncured components may comprise female tools or both female tools and male tools. The two or more cured composite assemblies may comprise one or more of carbon and fiberglass composite materials.

A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.

An apparatus is provided for rotational equipment. This apparatus includes a rotor blade including an airfoil body, a spar structure and a cuff. The airfoil body extends spanwise from a base to a tip. The airfoil body extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil body extends laterally between a first side and a second side. The spar structure extends spanwise within and supports the airfoil body. The cuff projects out from the spar structure and away from the base of the airfoil body. The cuff is formed integral with the spar structure. The cuff and the spar structure are configured from or otherwise include thermoplastic material.

A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.

Composite profiles, such as rotor blades, airfoils, I-beams, and box beams having non-uniform cross sections, and a system, method and process for pultrusion of composite profiles. The pultrusion of a heavier or thicker cross section portion of the composite profile is performed in-line and upstream from pultrusion of a thinner or lighter portion of the pultruded profile using a separate die for the thicker portion of the cross section, or leading edge slug, in order to optimize the processing conditions, productivity, and consistency of the composite profiles.

A composite assembly has an outer spar component having an outer spar component inner profile, an inner spar component having an inner spar component outer profile substantially complementary to the outer spar component inner profile, and an adhesive disposed between the outer spar component and the inner spar component.

An apparatus for securing first and second skins to a core in a composite rotor blade includes an elongated member configured to be installed through a passage in the core of the composite rotor blade. The elongated member has a first end configured to be attached to an outer surface of the first skin and a second end configured to be attached to an outer surface of the second skin. The apparatus also includes a first patch configured to adhere the first end to the outer surface of the first skin, and a second patch configured to adhere the second end to the outer surface of the second skin such the elongated member extends from the outer surfaces of the first and second skins through the passage in the core.

An elastic torsion element for connecting a rotor blade to a rotor hub of a rotor, the elastic torsion element comprising at least two elastically deformable plates, wherein each one of the at least two elastically deformable plates comprises fiber reinforced polymers, wherein respective fibers of the fiber reinforced polymers of each one of the at least two elastically deformable plates are at least arranged along one of a first and a second dominant fiber directions, wherein the first dominant fiber direction crosses the second dominant fiber direction in a predetermined fiber direction crossing region, and wherein the elastic torsion element comprises an integrated elastic lead-lag hinge that is formed at the predetermined fiber direction crossing region.

A rotor system for a rotary wing aircraft includes a rotor hub including a first beam attachment member and a second beam attachment member. A hub arm including a U-shaped beam member is connected to the rotor hub. The U-shaped beam member includes a first end portion, a second end portion and an intermediate section connecting the first and second end portions. The first end portion is connected at the first beam attachment member. The second end portion is connected at the second beam attachment member. A pitch change bearing is mounted between the first and second beam attachment member through the first end portion and the second end portion.

In one embodiment, a rotor blade may comprise a blade body, a spar structure, and a blade nose. The blade body may comprise a skin, wherein the skin is configured to form an airfoil shape, and wherein the airfoil shape comprises an inboard end, an outboard end, a leading edge, and a trailing edge. The spar structure may comprise a first spar cap and a second spar cap, wherein the first spar cap is coupled to an upper portion of the skin, and wherein the second spar cap is coupled to a lower portion of the skin. The blade nose may comprise a cavity, wherein the cavity is configured to house a plurality of modular weights at a plurality of radial blade locations, wherein the plurality of radial blade locations comprises a range of locations between the inboard end and the outboard end.