Method of constructing a hollow fiber reinforced structure

A method of constructing a hollow fiber reinforced airfoil, the airfoil including an exterior surface having a substantially convex suction side surface and a substantially concave pressure side surface, the method comprising the steps of:

• providing a spindle structure for defining a preform structure;
• providing a fiber structure comprising a fiber material and a matrix;
• placing said fiber structure around said spindle structure creating said preform structure having an interior volume;
• locating said preform structure within a mold, said mold having an interior surface having a substantially convex interior surface for defining said substantially concave pressure side surface and a substantially concave interior surface for defining said substantially convex suction side surface;
• moving an insert structure within said interior volume of said preform structure, said insert structure having an exterior surface, wherein said insert structure is expandable in at least one direction;
• reshaping said preform structure into a predetermined airfoil shape defined by said interior surface of said mold and said exterior surface of said insert structure to define a reshaped preform structure;
• and
• conditioning said reshaped preform structure creating a finished hollow fiber reinforced airfoil.