Patent ID: 8840750

Claim:
A method for forming a fan blade, the method comprising the steps of: applying an adhesive layer around a leading edge of a fan blade body, wherein the adhesive layer includes an adhesive film supported by a scrim cloth, and the adhesive layer contacts a portion of an inner surface of the fan blade body and a portion of an outer surface of the fan blade body; then positioning a leading edge sheath relative to the fan blade body such that a first flank of the leading edge sheath is positioned over the portion of the inner surface of the fan blade body and a second flank of the leading edge sheath is positioned over the portion of an outer surface of the fan blade body, wherein there is a gap between the leading edge sheath and the fan blade body; applying pressure to the first flank and the second flank of the leading edge sheath to secure the leading edge sheath to the blade body; and curing the adhesive film, wherein the step of curing the adhesive expands the adhesive film to fill the gap.