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

An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member comprising:

• an upper skin;
• a lower skin;
• and
• a support network having a plurality of interconnected support members in a lattice arrangement, the support network being configured to provide tailored characteristics of the airfoil member.

An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member comprising:

• an upper skin;
• a lower skin;
• and
• a support network having a plurality of interconnected support members in a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member.

A method of repairing an airfoil member, comprising:

• removing a damaged portion of the airfoil member to form a cavity;
• designing at least one of a virtual upper skin, a virtual lower skin, a virtual support network, and components therefor for the cavity;
• forming at least one of the upper skin, the lower skin, the support network, and components therefor using an additive manufacturing process;
• and
• bonding the at least one of the upper skin, the lower skin, the support network, and components therefor to the cavity in the airfoil member.