Method of making composite fan blade

摘要

A method of forming a composite airfoil having a suction side and pressure side includes the steps of designing a mold (36), designing a woven core (38), designing a plurality of plies (40) and assembling the designed mold, core and plies to create the composite airfoil. The hollow mold has an inner surface which defines the surface profile of the composite airfoil. The plurality of plies is designed to fit between the inner surface of the mold and an outer surface of the woven core. The plurality of plies is designed after the step of designing the woven core.