Abstract: A method of making a sheath for an airfoil may include the steps of forming an upper sleeve and a lower sleeve, and forming a central portion bonded to the upper sleeve and the lower sleeve. The central portion may be formed by depositing a material on the upper sleeve and the lower sleeve. A portion of the material may be removed from at least one of the central portion, the upper sleeve, or the lower sleeve. The sheath may include a first flank, a central portion bonded to the first flank, and a second flank bonded to the central portion. The central portion may have a substantially uniform microstructure resulting from additive manufacturing.

Abstract: A method of making a sheath for an airfoil may include the steps of forming an upper sleeve and a lower sleeve, and forming a central portion bonded to the upper sleeve and the lower sleeve. The central portion may be formed by depositing a material on the upper sleeve and the lower sleeve. A portion of the material may be removed from at least one of the central portion, the upper sleeve, or the lower sleeve. The sheath may include a first flank, a central portion bonded to the first flank, and a second flank bonded to the central portion. The central portion may have a substantially uniform microstructure resulting from additive manufacturing.

Abstract: A method of making a fan blade may include the steps of forming a core comprising fibrous material, and placing a first layer of dry fiber tows over the core using a robot. The first layer of dry fiber tows may be substantially un-crimped and may have a thermoplastic coating. A second layer of dry fiber tows may be placed over the first layer of dry fiber tows using the robot. The second layer may be un-crimped and coated similar to the first layer. The core, the first layer, and the second layer may be molded using resin transfer molding. The first layer may be placed over the core in a curved configuration. The core may include a three-dimensionally woven core formed on a loom and/or a plurality of layers of dry fiber tows placed by the robot.

Abstract: A method of making a sheath for an airfoil may include the steps of forming an upper sleeve and a lower sleeve, and forming a central portion bonded to the upper sleeve and the lower sleeve. The central portion may be formed by depositing a material on the upper sleeve and the lower sleeve. A portion of the material may be removed from at least one of the central portion, the upper sleeve, or the lower sleeve. The sheath may include a first flank, a central portion bonded to the first flank, and a second flank bonded to the central portion. The central portion may have a substantially uniform microstructure resulting from additive manufacturing.

Abstract: A method of making a fan blade may include the steps of forming a core comprising fibrous material, and placing a first layer of dry fiber tows over the core using a robot. The first layer of dry fiber tows may be substantially un-crimped and may have a thermoplastic coating. A second layer of dry fiber tows may be placed over the first layer of dry fiber tows using the robot. The second layer may be un-crimped and coated similar to the first layer. The core, the first layer, and the second layer may be molded using resin transfer molding. The first layer may be placed over the core in a curved configuration. The core may include a three-dimensionally woven core formed on a loom and/or a plurality of layers of dry fiber tows placed by the robot.

Abstract: A part identification system includes a part made of at least a first material having a first density, and an identifier made of a second material embedded in the first material and having a second density greater than the first density, and wherein the identifier is visually invisible. A security reader of the system is constructed and arranged to read the identifier and may be a radiographic reader. A method of manufacturing the part may include additive manufacturing.