Methods of customizing, manufacturing, and repairing a rotor blade using additive manufacturing processes

A method of making a rotor blade, comprising:

• providing a data library, the data library comprises dynamic performance data, characteristics of materials, support network arrangement parameters, upper skin parameters, and lower skin parameters;
• designing at least one of an upper skin and a lower skin, the designing step is based upon, at least in part, the dynamic performance data, the characteristics of materials, the upper skin parameters, and/or the lower skin parameters in the data library;
• designing a support network having a tailored cell density and adjacent to the upper skin and/or the lower skin, the designing step is based upon, at least in part, the dynamic performance data, the characteristics of materials, and the support network arrangement parameters in the data library;
• forming the support network using an additive manufacturing process;
• and
• forming at least one of the upper skin and the lower skin using an additive manufacturing process.