Method of manufacturing a composite blade with a reinforced leading edge

A method of manufacturing a composite propulsor blade having an axially extending load bearing spar disposed within a fiber reinforced shell defining an airfoil comprising the steps of:

• forming a spar assembly that carries the load absorbed by the propulsive blade having a leading edge, a trailing edge, and a pressure side and a suction side extending therebetween;
• wrapping one sheet of fabric material of substantially uniform thickness that is precut to a length exceeding the full extent of the airfoil including the pressure side and suction side defining a blanket about said spar assembly whereby said spar assembly is covered by a fabric wrap by wrapping said one sheet about said spar assembly such that said one sheet overlaps itself at the leading edge so that said fabric wrap has a first relatively uniform thickness overlapping the leading edge of said spar assembly and a second uniform thickness overlapping the remainder of said spar assembly, said first thickness being about twice the thickness as said second thickness;
• and
• impregnating said one sheet of fabric material with a curable resin material whereby upon subsequent curing of the resin material a fiber reinforced shell having an approximately double thick leading edge portion is formed about the spar assembly.