Abstract: A method of manufacturing a planet carrier of a gearbox comprises manufacturing a plurality of preforms. Each preform comprises a base portion, a first end portion connected to a first end of the base portion, a second end portion connected to a second end of the base portion, a first side portion connected to a first side of the base portion, a second side portion connected to a second side of the base portion and a top portion. The first and second end portions and the first and second side portions are folded relative to the base portion and the top portion is folded and the adjacent edges of the portions of each preform are secured together to form a support structure. A first ring and a second ring are manufactured. The first and second end portions of each support structure are secured to the first and second rings respectively.

Abstract: A gearbox includes a sun gear, a plurality of planet gears, an annulus gear and a planet carrier. The planet carrier includes a first ring, second ring spaced axially from the first ring, a plurality of circumferentially spaced axles and a plurality of circumferentially spaced support structures extending axially between and secured to the first ring and second ring. Each planet gear is rotatably mounted on a respective one of the axles. The first ring has a plurality of circumferentially spaced recesses and the second ring has a plurality of circumferentially spaced recesses. Each recess in the second ring is aligned with a corresponding one of the recesses in the first ring. A first end of each support structure locates in a recess in the first ring. A second end of each support structure locates in a recess in the second ring. Each support structure comprises a fused powdered material.

Abstract: A method of manufacturing a planet carrier of a gearbox comprises manufacturing a plurality of preforms. Each preform comprises a base portion, a first end portion connected to a first end of the base portion, a second end portion connected to a second end of the base portion, a first side portion connected to a first side of the base portion, a second side portion connected to a second side of the base portion and a top portion. The first and second end portions and the first and second side portions are folded relative to the base portion and the top portion is folded and the adjacent edges of the portions of each preform are secured together to form a support structure. A first ring and a second ring are manufactured. The first and second end portions of each support structure are secured to the first and second rings respectively.

Abstract: A gearbox includes a sun gear, a plurality of planet gears, an annulus gear and a planet carrier. The planet carrier includes a first ring, second ring spaced axially from the first ring, a plurality of circumferentially spaced axles and a plurality of circumferentially spaced support structures extending axially between and secured to the first ring and second ring. Each planet gear is rotatably mounted on a respective one of the axles. The first ring has a plurality of circumferentially spaced recesses and the second ring has a plurality of circumferentially spaced recesses. Each recess in the second ring is aligned with a corresponding one of the recesses in the first ring. A first end of each support structure locates in a recess in the first ring. A second end of each support structure locates in a recess in the second ring. Each support structure comprises a fused powdered material.