US Patent 10391722 Method of producing aerofoils

The invention provides a method of molding composite material aerofoil, comprising steps of (i) providing a mold having the desired three-dimensional shape; (ii) providing a first layer over the mold that adheres to the mold and has a non-adhesive outer surface; (iii) applying composite material over the first layer; (iv) laying a moldable sheet over the composite material; (v) curing the resulting assembly and (vi) removing the moldable sheet and mold to leave an intact one-piece aerofoil structure.