Rolls-royce Corporation

Vincent Gill

Robert C Backhouse

Jia Li

Seok Woo Lee

A method of manufacturing a composite fan blade with an outer part and a core includes laying up a plurality of continuous plies to achieve a stack, placing the core on a central portion of the stack of continuous plies to achieve an unfolded preform; folding the contin-uous plies about the core, such that the central portion of the stack folds about the core and the first portion is superimposed to the second portion, to achieve a folded preform; apply-ing pressure to the folded preform to achieve a consolidated curved folded preform; curing the consolidated curved folded preform to achieve the composite fan blade.

Composite fan blade and manufacturing method thereof

A method of forming a composite article involves the steps of:

Method for forming a composite article

A method of manufacturing a fan blade for a gas turbine engine. The method includes providing a compression mould having an internal mould surface corresponding to an outer profile of a fan blade, providing opposing first and second laminates to form a shell corresponding to the mould surface, each laminate comprising a lay-up of plies of fibre reinforcement material, applying a core material comprising quasi-isotropic short fibre reinforced resin in the compression mould so that with the compression mould in a moulding configuration the core material is enclosed by the shell, the core material and the shell forming a pre-form for the fan blade, applying pressure to compress the pre-form so that it conforms to the mould surface, and applying heat to cure the pre-form.

Method of manufacturing a fan blade and a fan blade

There is disclosed a method of manufacturing a fan blade for a gas turbine engine, the method comprising: providing a root insert comprising quasi-isotropic short fibre reinforced resin, providing a first sub-laminate of a fibre-reinforcement pre-form for the fan blade on a first mould surface, placing the root insert on the first sub-laminate at a position corresponding to a root of the fan blade, providing a second sub-laminate of the pre-form over the root insert and the first-sub-laminate, so that the root insert is at an intermediate position between the first and second sub-laminates; and applying heat and pressure to form the pre-form.

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Bristol, United Kingdom

Vincent Gill