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"Since our offshore blade factory opened in Hull in 2016, Siemens Gamesa has proudly served as the catalyst for the powerful growth the area has seen. The rapid development of the offshore
Rolls-Royce (London, U.K.) has started manufacture of the world’s largest fan blades, for its UltraFan demonstrator engine that will set new standards in efficiency and sustainability. This milestone marks the official start of parts production for the demonstrator.
Composite fan blade in production at the Rolls-Royce composite technology center in Bristol, U.K. SOURCE for all images | Rolls-Royce Rolls-Royce (London, U.K.) has started manufacture of the world’s largest fan blades, for its UltraFan demonstrator engine that will set new standards in efficiency and sustainability.
Similarly, Rolls-Royce's Fan Blade Singapore (FBSG) facility started its journey in 2012, with the first set of fan blades manufactured within the company’s Seletar Campus. Over the years, FBSG has continued to evolve, and is now Rolls-Royce's leading manufacturing facility for its hollow titanium wide chord fan blades.
FBSG currently produces 4,800 fan blades per year with today’s demand. Since its inception a decade ago, FBSG has never stopped growing – it has unceasingly improved processes, streamlined cross-disciplinary workflows, adopted new technologies, and focused on people development to raise performance levels.
The fan blades are created through the build-up of hundreds of layers of carbon-fibre materials, pre-filled with state-of-the-art, toughness-enhanced, resin material. Heat and pressure are then applied, and each blade is finished with a thin titanium leading edge, which offers extreme protection against erosion, foreign objects and bird strikes.
They are being made at the company’s technology hub in Bristol, U.K. The fan blades are made from 500 plies of Hexcel’s (Stamford, Conn. U.S.) HexPly M91 carbon fiber-reinforced, high-toughness and impact-resistant epoxy prepreg. Hexcel supplies the slit tape for automated layup.