The blades begin with a 3d-printed mould
After mould release is applied on the mould, 3 layers of carbon fiber fabric is layered on top of each other and bonded with an epoxy resin. Creating the outer shell of the blade.
The empty mould cavity with the carbon fiber shell is then filled with a mixture of polyurethane resin and milled fiber glass, creating a rather flexible core to compliment the stiff shell. A fiberglass repair kit was used to fill up any uneven or broken surfaces. After all the blades are made a final layer of epoxy resin coats the surface of the blades to provide a smoother and finer finish.
Composite blades after completion, the polyurethane and milled fiberglass gave the blades a white finish.