Patent ID: 8551382

Claim:
A method of forming a blade stiffener, comprising: using a layup charge of stiffener-forming material and a blade-forming assembly having a first tool die, a second tool die, a tool gap between the first tool die and the second tool die, a first forming cavity in the first tool die, and a second forming cavity in the second tool die, wherein using comprises bridging the tool gap with the layup charge to form a blade arm connecting portion; placing a blade filler on the blade arm connecting portion at the tool gap; pressing, using a forming bar, said blade filler through the tool gap between the first tool die and the second tool die until the blade filler reaches and extends into the first forming cavity and the second forming cavity; removing the forming bar; and pressing said tool dies together such that a first side of the layup charge contacts the first forming cavity in the first tool die and the second forming cavity in the second tool die, and an opposite side of the layup charge contacts the blade filler, and the blade arm connecting portion extends between the first tool die and the second tool die, with the tool gap being substantially eliminated.