Beginning in [2009], Continuum Dynamics Inc worked with Erickson Helicopters on their project to design, manufacture and receive FAA certification for new composite main rotor blades for the global S-64 Skycrane helicopter fleet.
Given that the existing stock of legacy main rotor blades were approaching their life limit, this program was not only an opportunity to improve performance, but necessary to keep the fleet in the air. CDI applied our aerodynamics and aeromechanics expertise and in house software to evaluate the Skycrane’s legacy rotor blades, before supporting Erickson and other team members in designing a bolt on replacement main rotor blade. The original S-64 blades used symmetrical NACA airfoils and a rectangular planform, which provided ample opportunity to increase performance through the application of analysis, airfoils, planform and materials. Through high fidelity analysis of both aerodynamic performance and structural behavior, CDI produced a design which achieved lifting capability under high/hot conditions, reduced fuel burn, and which required no modification to the existing airframe.
Flight testing occurred from 2015 through 2018, with full FAA approval received in 2020. To date over 90 of these new composite blades have been manufactured, extending the life of the global S64 fleet. If you want to learn more about this program, Erickson helicopters has also written a case study on their experience of designing, manufacturing and certifying a new composite rotor blade