US Patent 12116903 Composite airfoils with frangible tips

Composite airfoils and methods for forming composite airfoils are provided. For example, a composite airfoil of a gas turbine engine comprises opposite pressure and suction sides extending radially along a span from a root to a tip, which define opposite radial extremities of the airfoil. The composite airfoil further comprises a body section and a tip section, which includes the tip, that each extend radially along the span. The composite airfoil is formed from a composite material comprising fibers disposed in a matrix material. The tip section has a tip fiber volume, and the body section has a body fiber volume that is greater than the tip fiber volume. Another composite airfoil comprises a tip cap applied over the tip that tapers from a first end to a second end such that each of the pressure and suction side walls of the tip cap narrows from a first thickness to a second thickness.