Product Development Procedure

Utilizing in-house developed code, a preliminary blade design is created to meet the aerodynamic and performance requirements set forth by the project.
With a known blade design in hand, customized code creates a 3-dimensional representation of the blade complete with material properties and proper constraints. Given flight conditions (air speed, blade angle, etc.) this code will apply the appropriate pressure loads along the length of the blade and prepare it for final analysis. This allows for an accurate depiction of blade steady and cyclic stresses, deflections, resonant frequencies and mode shapes.
A custom mold is designed and machined to produce the desired blade shape. While the mold is generally made from aluminum, research is being done into alternative high-speed, low-cost tooling options such as epoxy. The blade lay-up is then introduced into the Resin Transfer Molding procedure where the carbon fiber and fiberglass braids are bonded together. Other parts crucial to the assembly are also acquired or machined as necessary.
Once the required parts have been machined or molded, construction of the final assembly can begin. Each product is carefully constructed by hand by a knowledgeable member of the staff. General testing procedures will also be performed to ensure the product performs as specified.
Upon completion of all quality checks and product testing, the final assembly is ready to be delivered to the customer.