3D Woven Composite Turbine Blade Preform

The invention segments the manufacturing process by using pre-woven three-dimensional preforms that come in ready-to-use configurations, eliminating the need for manual stacking of individual plies. The preforms are designed with integrated fiber orientations that match the final blade geometry, allowing direct placement into molds without complex assembly operations.

The fiber reinforcement structure is pre-formed into three-dimensional woven preforms before the molding process. These preforms are prepared in advance with the correct geometry, fiber distribution, and orientation patterns, so that when placed in the mold, they require minimal additional manipulation and no manual stacking operations.

The preforms are pre-shaped and pre-compacted to very close tolerances before polymerization, anticipating the final blade geometry. The three-dimensional weaving pattern and pre-forming process create surfaces that require minimal post-processing, preserving fiber continuity while achieving the required dimensional accuracy for contours and bearing surfaces.

The invention changes the physical state and properties of the preform through controlled compaction and pre-forming operations. By adjusting density, fiber orientation, and surface finish parameters during the pre-forming stage, the material achieves near-final dimensions and surface quality, reducing the need for aggressive machining that would cut fibers.

The invention merges the protective element installation with the injection molding process itself. Protective coatings, surface treatments, or reinforcement layers are applied to the preform before or during polymerization, so that the blade emerges from molding already equipped with its protective elements. This eliminates separate post-processing steps and reduces total implementation time.

Protective elements are pre-installed on the preform before the injection molding operation. Surface coatings, protective films, or reinforcement layers are applied in advance, and the preform is then molded with these protective elements already in place, integrating protection into the primary manufacturing step rather than adding it later.

The invention uses three-dimensional woven preforms that are internally segmented into functional zones through the weaving pattern itself, rather than assembling separate physical components. Different regions of the preform can have different fiber orientations, densities, or material properties built into the weave structure, providing design flexibility without creating weak interfaces between joined parts.

The invention employs three-dimensional woven composite preforms where multiple fiber directions and layers are integrated into a single continuous structure. This creates a monolithic composite material with through-thickness reinforcement and interlaced fiber paths that prevent delamination, eliminating the need to assemble separate components that would create vulnerable joint zones.