Composite fan blade and manufacturing method thereof

A method of manufacturing a composite fan blade extending spanwise from a root to a tip, chordwise from a leading edge to a trailing edge, the composite fan blade comprising an outer part and a core, the outer part defining a pressure surface wall extending from the leading edge to the trailing edge and a suction surface wall extending from the leading edge to the trailing edge, the method comprising:

• laying up a plurality of continuous plies extending along a longitudinal direction from a first end to a second end to achieve a stack of continuous plies, the stack comprising a first portion corresponding to the pressure surface wall, a second portion corresponding to the suction surface wall, and a central portion corresponding to the root, wherein the first end corresponds to a pressure surface tip region of the composite fan blade and the second end corresponds to a suction surface tip region of the composite fan blade;
• placing the core on the central portion of the stack of continuous plies to achieve an unfolded preform;
• folding the continuous plies about the core, such that the central portion of the stack folds about the core and the first portion is superimposed to the second portion, to achieve a folded preform;
• applying pressure to the folded preform to achieve a consolidated curved folded preform;
• and
• curing the consolidated curved folded preform to achieve the composite fan blade;
• wherein
• in the folding step the central portion of the stack folds about the core so as to form the root, and the first portion and the second portion extend in a spanwise direction between the root and respective tip regions.