US Patent 10309241 Compound fillet varying chordwise and method to manufacture

An improved structure and method of manufacturing a structure such as a guide vane for a gas turbine engine includes an improved guide vane having a stress transition section called a fillet that is positioned between an airfoil and a hub. The fillet includes a constant radius section and a compound radius portion that is collectively configured to handle the stress loads of the guide vane as well as to provide aerodynamic efficiencies. An improved method of manufacturing an airfoil is provided that employs a single pass manufacturing process whereby a single tool is used to generate a resulting fillet having a constant radius and compound radius portion.