Fully integral epoxy cap probe

A gas turbine engine comprising:

• a fan having a blade having a tip;
• a fan case having an inner aerodynamic surface and a rub strip;
• the tip proximate the inner aerodynamic surface;
• and
• a fully integral epoxy cap probe, comprising:
• a body having a cavity disposed radially outward of the tip and comprising a first material;
• a frame disposed within the cavity and comprising a second material;
• a first sensor element and a ground plane disposed within the frame, the first sensor element and the ground plane comprising a third material, wherein the second material and the third material are at least one of a resin, epoxy, and/or thermoset material;
• and
• a first soft lead in electronic communication with the first sensor element and the ground plane.

A method of manufacturing a fully integral epoxy cap probe, the method comprising:

• forming a cavity having a sidewall in a first material radially outward of a fan blade;
• forming a frame comprising a backplane and an enclosing wall, the enclosing wall extending perpendicular to the backplane and defining a pocket radially inward of the enclosing wall, wherein the frame comprises a second material;
• disposing the frame in the cavity such that the enclosing wall and the sidewall define a trench between the sidewall and the enclosing wall radially outward of the enclosing wall;
• inserting a soft lead comprising a lead wire and a lead shield into the frame wherein the lead shield is disposed within the trench and the lead wire is disposed within the pocket;
• filling the trench and the pocket with a third material and filling a remainder of the cavity with the second material;
• and
• curing the first material, the second material, and the third material to form a monolithic structure.