Abstract: A method for manufacturing a structural component of a blade segment for a rotor blade includes providing a mold of the structural component having an outer wall that defines an outer surface of the structural component. The method also includes laying up one or more fiber layers in the mold so as to at least partially cover the outer wall. As such, the fiber layer(s) form the outer surface of the structural component. Further, the method includes providing one or more metal mesh layers having one or more ends. Moreover, the method includes providing a cover material to the end(s) of the metal mesh layer(s). In addition, the method includes placing the metal mesh layer(s) with the covered end(s) atop the fiber layer(s). Thus, the method includes infusing the fiber layer(s) and the metal mesh layer(s) together via a resin material so as to form the structural component.

Abstract: A method for producing a hollow composite structure, such as a spar beam for a wind turbine blade, includes placing a membrane within a mold tool, the membrane being permeable to air and impermeable to resin. A mandrel is placed within the mold tool, the mandrel enclosed in an air tight layer that includes a vent. Fiber reinforcement material is placed around the mandrel within the mold tool and the membrane is sealed at least partly around the fiber reinforcement material and mandrel. The mold tool is closed with the vent line from the mandrel extending through the sealed membrane to outside of the mold tool. A vacuum is drawn in the mold tool while the mandrel is vented to outside of the mold tool, and while the vacuum is being drawn, resin is infused into the mold tool around the mandrel such that the resin is drawn towards the membrane.

Abstract: A method for producing a hollow composite structure, such as a spar beam for a wind turbine blade, includes placing a membrane within a mold tool, the membrane being permeable to air and impermeable to resin. A mandrel is placed within the mold tool, the mandrel enclosed in an air tight layer that includes a vent. Fiber reinforcement material is placed around the mandrel within the mold tool and the membrane is sealed at least partly around the fiber reinforcement material and mandrel. The mold tool is closed with the vent line from the mandrel extending through the sealed membrane to outside of the mold tool. A vacuum is drawn in the mold tool while the mandrel is vented to outside of the mold tool, and while the vacuum is being drawn, resin is infused into the mold tool around the mandrel such that the resin is drawn towards the membrane.

Abstract: A method for manufacturing a structural component of a blade segment for a rotor blade includes providing a mold of the structural component having an outer wall that defines an outer surface of the structural component. The method also includes laying up one or more fiber layers in the mold so as to at least partially cover the outer wall. As such, the fiber layer(s) form the outer surface of the structural component. Further, the method includes providing one or more metal mesh layers having one or more ends. Moreover, the method includes providing a cover material to the end(s) of the metal mesh layer(s). In addition, the method includes placing the metal mesh layer(s) with the covered end(s) atop the fiber layer(s). Thus, the method includes infusing the fiber layer(s) and the metal mesh layer(s) together via a resin material so as to form the structural component.