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.

The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof, e.g. using 3D printing. In one embodiment, the method includes forming a rotor blade structure having a first surface and an opposing, second surface, the first and second surfaces being substantially flat. Another step includes printing a leading edge segment of the rotor blade onto the first surface, wherein heat from the printing bonds the leading edge segment to the first surface. The method also includes rotating the rotor blade structure having the leading edge segment attached thereto. A further step includes printing a trailing edge segment of the rotor blade onto the second surface, wherein heat from the printing bonds the trailing edge segment to the second surface. Another step includes securing one or more fiber-reinforced outer skins to the leading and trailing edge segments so as to complete the rotor blade.

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 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.

A method for accurately producing the drilled hole in a wall of a component fabricated by investment casting process, such as for use in a blade or steam turbine includes the following steps. The 3D data of actual component is obtained from the measurements or from the numerical simulation. The actual model and the ideal model are aligned and compared, a series of cutting planes are given to establish a series of 2D cross-sections of the actual and ideal models after registration. Each cross-section is dispersed into discrete points, the distance between each corresponding points are calculated and formed into 2D displacement. The accurate parametric model consisting of the depth, hole center, and the nominal vector is obtained on the basis of considering the deviations in geometrical and positional values. The drilled hole is then produced according to the corrected parametric drilled-hole geometrical and positional value.

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.

The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof, e.g. using 3D printing. In one embodiment, the method includes forming a rotor blade structure having a first surface and an opposing, second surface, the first and second surfaces being substantially flat. Another step includes printing a leading edge segment of the rotor blade onto the first surface, wherein heat from the printing bonds the leading edge segment to the first surface. The method also includes rotating the rotor blade structure having the leading edge segment attached thereto. A further step includes printing a trailing edge segment of the rotor blade onto the second surface, wherein heat from the printing bonds the trailing edge segment to the second surface. Another step includes securing one or more fiber-reinforced outer skins to the leading and trailing edge segments so as to complete the rotor blade.

A method for accurately producing the drilled hole in a wall of a component fabricated by investment casting process, such as for use in a blade or steam turbine includes the following steps. The 3D data of actual component is obtained from the measurements or from the numerical simulation. The actual model and the ideal model are aligned and compared, a series of cutting planes are given to establish a series of 2D cross-sections of the actual and ideal models after registration. Each cross-section is dispersed into discrete points, the distance between each corresponding points are calculated and formed into 2D displacement. The accurate parametric model consisting of the depth, hole center, and the nominal vector is obtained on the basis of considering the deviations in geometrical and positional values. The drilled hole is then produced according to the corrected parametric drilled-hole geometrical and positional value.