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.

A method of forming a rotor blade, including forming at least one of a partial upper skin, a partial lower skin, and a partial support network using an additive manufacturing process; and forming a first receptacle in at least a one of the partial upper skin, the partial lower skin, and the partial support network using the additive manufacturing process. The first receptacle is configured to receive of at least one of an electronic component and a mechanical component. In some embodiments, there is a method of manufacturing a rotor blade that includes forming a first locating receptacle in at least one of the upper skin, the lower skin, and the support network using the additive manufacturing process; and positioning at least one of the upper skin, the lower skin, and the support network in a desired position on a fixture based, in part, on the first locating receptacle.

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 intentionally activated frangible bonding system comprises a frangible adhesive, adhesive primer, composite material matrix, and/or the like, having a polydispersion of at least one additive spread throughout the frangible bonding material. The additive degrades a bond provided by the frangible bonding material, upon application of a specific energy to the frangible bonding material. An energy emitter is configured to selectively direct the specific energy toward a structure or assembly comprising components bonded by the frangible bonding material to degrade the frangible bonding material bonding the components for disassembly.

An afterbody for a rotor blade of a rotorcraft is unitarily formed of a single material of construction. The afterbody includes an upper surface disposed from a lower surface, a concave leading edge connected to the upper surface and the lower surface, and a trailing edge formed at an intersection of the upper surface with the lower surface.

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.

A system and method for attaching a damper to a tail rotor blade includes a cuff that is integral with the rotor blade. The cuff has upper and lower lugs formed by extending a skin over a blade core of the rotor blade. The skin extends past the blade core to the root end of the rotor blade. The rod end of the damper is inserted into an opening between the lugs. The rod end of the damper is coupled to the blade with a bolt through aligned holes in the lugs. The cuff also couples the rotor blade to the grip inside the cuff. The cuff includes a same material as that forming the skin. Sacrificial buffer pads are applied to interior faces of the lugs. The buffer pads permit a distance between the lugs to be machined within a tolerance without removing skin from the cuff.

An airfoil member can have a root end, a tip end, a leading edge, and a trailing edge. The airfoil member can include an upper skin, a lower skin, and a composite core member having a plurality of cells, an upper surface network of the cells can be bonded to the upper skin, a lower surface network of the cells can be bonded to the lower skin. The composite core can have a septum layer embedded in the cells that form the composite core, the septum layer being configured to provide tailored characteristics of the airfoil member.

A blade of a rotor for a rotary-wing aircraft is equipped with an outer covering extending along the span of the blade. This outer covering is provided with an extrados skin and with an intrados skin defining a cavity. The blade also includes a structure that extends into the cavity and connects the blade to a hub of the rotor. The cavity is filled with a filling material that includes at least one partition parallel to a chord of the blade and at least two independent blocks of filling material filling the cavity, thereby allowing the reduction of the torsional rigidity along the span of the blade.

A method of constructing a mandrel generally complementary to a spar cavity of a spar includes connecting a first component and a second component to form a central space there between and inserting a center component within the central space such that the center component retains the first component and second component in a desired position forming an outer surface of the mandrel which corresponds to an inner surface of the spar cavity.