The Composite Main Rotor Tool

The centrepiece of our recent work is the massive, matched metal tool you can see in the video. This is what will form the carbon fibre structure of the HX50's main rotor blades—the spar, the trailing edge, and the leading edge.

Here’s a breakdown:

• Machining Complete: Both the top and bottom halves of the tool are now fully machined.
• Perfect Fit & Finish: The tools have undergone a meticulous surface polishing treatment. We've also assembled and disassembled them to guarantee a perfect fit.
• Verified Precision: Geometric inspections have been completed, confirming that the tools meet our exceptionally tight tolerances. This precision is non-negotiable for producing perfectly identical and aerodynamically efficient blades.
• Preparing for Curing: The next step is to install heater cartridges into the holes running down the length of the tool. These will allow us to manage a controlled temperature ramp-up and ramp-down during the curing process, which is absolutely vital for the strength and integrity of the composite blades.

This tool is the key to creating the lightweight, high-performance carbon fibre core of our rotor blades.

Forging the Erosion Shield

While the main tool crafts the composite body, a blade's leading edge requires extra protection from the elements. This is the job of the erosion shield, which we manufacture separately using metal forming processes.

For the long, relatively straight sections of the blade, we use a press-forming technique. Here’s the latest update on that front:

• Press Tool Ready: We have successfully produced the male and female parts of the metal press tool. This will be used to stamp sheets of stainless steel into the precise aerofoil shape required for the erosion shield.
• Trials Beginning Soon: We are scheduled to begin pressing trials in the coming days.
• Synchronised Production: Our goal is to have the finished erosion shields ready to be bonded to the first composite blades as soon as they come out of the laminating shop, ensuring a smooth and efficient production workflow.