Composite aerofoil

A method of manufacturing a composite aerofoil, the composite aerofoil comprising:

• a root;
• a leading edge;
• a trailing edge;
• a concave pressure surface wall;
• a convex suction surface wall;
• and
• a tip,
• the method comprising:
• weaving a three-dimensional arrangement of reinforcing fibres such that a first set of reinforcing fibres extending generally longitudinally of the aerofoil from the root to the tip, a second set of reinforcing fibres extending generally chordally of the aerofoil from the leading edge to the trailing edge, and a third set of reinforcing fibres having portions extending generally chordally of the aerofoil and portions extending transversely to the first set of reinforcing fibres and to the second set of reinforcing fibres, the third set of reinforcing fibres crossing and interlocking with the first set of reinforcing fibres and the second set of reinforcing fibres, the three-dimensional arrangement of woven reinforcing fibres defining a plurality of cavities, the plurality of cavities being spaced apart between the leading edge and the trailing edge, the composite aerofoil comprising at least one web extending between, and being secured to, the concave pressure surface wall and the convex suction surface wall to produce a Warren girder structure, the three-dimensional arrangement of woven reinforcing fibres being arranged to produce the concave pressure surface wall, the convex suction surface wall and at least one web to produce the Warren girder structure;
• infiltrating a matrix material around the three-dimensional arrangement of woven reinforcing fibres;
• and
• heating and pressurizing the matrix material to consolidate and cure the composite material to produce the composite aerofoil.