Abstract: A wind turbine blade includes a pressure side shell member with an internal side spar cap, and a suction side shell member with an internal side spar cap. A box-shaped shear web assembly spans between the spar caps and has a generally hollow interior volume. The shear web assembly includes end walls affixed to a respective spar cap and spaced-apart side walls extending transversely between the end walls. The end walls and side walls define a continuous box-shaped assembly structurally interposed between the spar caps. Methods are also provided for making the box-shaped shear web assembly.

Abstract: A rotor blade for a wind turbine that includes an airfoil comprising a shell that includes an outer skin disposed around a plurality of fiber ribs. The fiber ribs may comprise resin-infused linear rib-like structures of substantially unidirectional fiber. The fiber ribs may be configured to include a plurality of junctions, the junctions comprising an intersection of two or more fiber ribs. The fiber ribs may be configured to form a repeating pattern along the inner surface of the outer skin.

Abstract: A method of manufacturing a rib-stiffened shell for a structure, wherein the rib-stiffened shell comprises an outer skin supported by a plurality of fiber ribs, the fiber ribs comprising thickened strips of substantially unidirectional fiber, and wherein the fiber ribs comprise a crisscrossing pattern that includes a plurality of junctions, the junctions comprising an intersection of two or more of the fiber ribs, the method comprising the steps of: configuring a convex mold, the shape of which corresponds to the contour of the outer skin of the structure; configuring a plurality of grooves in the convex surface of the convex mold that correspond to the pattern of the fiber ribs; laying up unidirectional fiber in the grooves of the convex mold; and applying the outer skin over the convex surface of the convex mold.