Fan Blades

Accelerate your efficiency

Fan blades often produce 90 % of an engine's thrust, making them crucial for jet-engine performance and efficiency. However, the fan blade's large size, unique geometries, and the variety of materials used in the manufacturing process create challenges for measurement and inspection. Inaccuracies in the shape of the leading edge and airfoil surface (bend, twist, and thickness) will decrease engine efficiency and thrust.

High accuracy and repeatable measurements are required throughout the fan blades' product lifecycle to ensure peak engine performance.

Quality gates along the production process of fan blades

The fan blade has undergone significant changes over the years and is easily noticeable to travelers. From the small "clapper" design to the current modern composite blades, their primary purpose remains to generate thrust during take-off, cruise, and landing. These blades are essential for engine efficiency, as they propel air around the bypass in the most efficient manner possible. The design of the airfoil, including the bow, sweep, twist, and lean, is engineered precisely, requiring high-quality tools like those available from ZEISS.

Metal fan blades

Metal fan blades, made mainly of aluminum and titanium, have been the go-to manufacturing method for jet engines since their inception. The design complexity of the blades has pushed the boundaries of manufacturing methods. Over time, the blades have evolved significantly from simple geometries and solid materials to three-dimensional swept airfoils with hollow or honeycomb structures. As these blades have evolved, the number of blades per engine has decreased while their size and cost of production have increased.

Click through all processes steps

  • Forging process

    The advanced tools and analysis from ZEISS can significantly improve traditional forging processes, resulting in increased productivity and higher accuracy rates on the first attempt.

    The challenge
    The die for the forging process is of paramount importance to the production of the fan blade. Ensuring the die and subsequent blades are conforming is where ZEISS technologies come in.

    Our solution
    ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the conformity of the blades and the life and wear of the die.

  • Airfoil edge finishing

    Airfoil edge finishing takes the forged airfoil, often with "squared edges," to the finish leading and trailing edge shapes. At this point, it's also common to check the internal cavities of the blade, be it honeycomb or web structures, for their integrity.

    The challenge
    The combination of the twist, lean, and edge shape makes the measurement and inspection task very demanding. The impact of tiny features on the edges, compared to the size of the blade, is challenging. For internal characteristics, the blade size and material properties are demanding.

    Our solution

    • Digitally capture and analyze in 2D and 3D the conformity of the whole airfoil, including the intricate edges.
    • ZEISS solutions measure the highest resolution and accuracy to analyze the edge: regular radius, elliptical shape, etc.
    • ZEISS offers CT solutions for checking the internals.
  • Root/tip machining

    The final machining ensures the part is fit for its intended final use. The tip clearances are critical to gas leakage to the casing and the root form for its precision fit to the fan disc.

    The challenge
    The overall size of the component, sometimes beyond 1.5 meters, in combination with the small tolerances on the root form, puts demands on selecting the right technology, probes, or sensors.

    Our solution
    The ZEISS solutions are complementary and can be used with tactile CMMs or ATOS ScanBox.

  • Final validation

    Regulatory and OEM requirements like AS9102 or AS13003 are necessary, stringent and comprehensive to fulfil.

    The challenge
    Fan blades are often deemed critical parts due to the impact if they fail in service, as such, the validation requirements to demonstrate airworthiness are some of the most demanding in the engine.

    Our solution

    • High-accuracy tactile, optical and microscopy solutions to fulfil thousands of characteristics necessary to validate
    • ZEISS Quality Suite helps to compile the results in an effective way
    • Specific software like Blade Inspect Pro enables to qualify every characteristic on part drawings or other standards in an efficient manner

Composite fan blades

Composite fan blades are an evolution of metal fan blade design, offering enhanced material properties and often enabling the blades to be significantly larger due to their lighter weight. But there’s a reason this hasn’t been done until more recently. The process requires high skill when produced manually and, otherwise, high levels of cost and development for automated processes. The result is a high-performing blade noticeable on the most modern jet engines.

Click through all processes steps

  • Carbon fiber layup and trim

    Modern manufacturing techniques need to complement modern analysis techniques.
    Carbon fiber fan blade processes are labor intensive and rely heavily on accurate shaping tools, and layup dies to produce the critical shape of the fan blade.

    The challenge
    The shaping die tool is critical to the creation of the overall shape of the blade and airfoil.
    and needs regular checks for wear.

    Our solution
    ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the die's conformity and its life and wear over.

  • Resin injection and curing

    Once the fiber has been laid, the resin is added, giving the rigidity, and the part is cured to its final airfoil shape.

    The challenge
    The final parts change organically with any forming, molding, and shaping process.

    Our solution
    ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the conformity to the part in the mold and when it's out to build the process understanding for long-term improvements.

  • Finish machining

    The final machining of the root and tip is critical to performance and function. The root forms have small tolerance requirements to match perfectly with the disc, and the tip dimensions are essential to ensure no gas leakage between the blade and the casing, which would introduce inefficiencies in the engine performance.

    The challenge
    The overall size of the component, sometimes beyond 1.5 meters, in combination with the small tolerances on the root form, puts demands on selecting the right technology, probes, or sensors.

    Our solution
    ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the conformity of the part in the mold and when it's out to build the process understanding for long-term improvements.

  • Metal leading edge

    The metal leading edge is a work of art. A single piece of freeform geometry is carefully bonded to the main carbon blade.

    The challenge
    Verifying the complex external and internal shape on the metal edge is time-consuming and expensive, often requiring dedicated fixturing.

    Our solution

    • ZEISS optical technology allows measurement of the external shape and form and removes the need for hard fixturing due to features like virtual clamping.
    • ZEISS tactile technologies additionally verify features with the highest accuracy.
  • Final validation

    Regulatory and OEM requirements like AS9102 or AS13003 are necessary, stringent, and comprehensive to fulfill.

    The challenge
    Fan blades are often deemed critical due to the impact if they fail in service; as such, the validation requirements to demonstrate airworthiness are some of the most demanding in the engine.

    Our solution

    • High-accuracy tactile, optical, and microscopy solutions fulfill thousands of characteristics necessary to validate.
    • ZEISS Quality Suite helps to compile the results in an effective way.
    • Specific software like ZEISS INSPECT Airfoil enables the efficient qualification of every characteristic on part drawings or other standards.

Repair and overhaul

Maintenance and repair are enormous cost factors throughout the entire product life cycle. Additionally, time is critical for getting fan blades back in the air. OEMs need high-speed measuring systems and software to anticipate service, failures, and overhauls now more than ever.

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