Abstract: Elongate articles of non-circular cross section such as those of an airfoil cross section are constructed by winding filamentary material in layers about a form between a pair of spaced turnarounds generally conforming in shape to the cross sectional shape of the form. Adjacent layers are continuously wound by winding the filamentary material across the edges and outer face of each turnaround while reversing the direction of relative longitudinal displacement between the filamentary material and the form. The shape correspondence between the turnarounds and the form effect a minimization of expanse between the turnaround edge and form surface, thereby minimizing bridging of the filamentary material between those two members.

Abstract: A method of manufacturing a filament wound article is practiced by winding overlying filamentary layers on a form such that those portions of the wound layers which are covered by overlying layers include incomplete or discontinuous portions thereof whereby portions of the layers which are not covered by overlying wound layers are of a minimum thickness for enhanced accuracy in the approximation of a desired smooth thickness profile.

Abstract: Filament band width uniformity is maintained in a filament winding process and apparatus therefor by a guide disposed between a winding eye and the mandrel about which the filaments are wound. The guide maintains a constant band payout angle with respect to the eye thereby maintaining uniform transverse reaction forces applied to the band by the eye.

Abstract: A hollow, stiff, one-piece filament-reinforced composite mandrel of nonuniform wall thickness for a wind turbine blade spar is comprised of bonded inner and outer filament-reinforced shells. The inner shell is fabricated by bonding together separately formed tubular halves. The outer shell is built up on the outer surface of the inner shell preferably by judicious winding of a plurality of turns of filament-reinforced epoxy resin material.