Abstract: An aerodynamic blade 12 and method of manufacture wherein the blade includes a tip 14, a root 16, materials comprising skins 18A, 18B, reinforcement strips 20A, 20B, 20C, 20D, glass sheets 22A, 22B, stiffeners 24A, 24B, and pre-cut sheets 26A, 26B, 26C, 26D layered into each of top and bottom molds 28, 30 using a resin 32 to define a mating perimeter 34 surrounding a depression 36 in said layered materials in each mold 28, 30. The molds 28, 30 are adapted to be mated together to engage the mating perimeters 34, and the depressions 36 define a core cavity 38. The molds 28, 30 are mounted to a mold bracket assembly 41 which enables the molds 28, 30 to be mated together after the blade 12 and materials are prepared. Each blade 12 further includes foam 40 disposed in the depressions 36 for filling the core cavity 38.