The use of paper honeycomb for prototype blade construction for small to medium-sized wind driven generators

Paper honeycomb is used for the construction of conventional, propeller-type, windmill blades. Using fairly simple techniques and conventional power tools, it is possible to shape both simple foils and more complex foils with or without tapered plan forms and with or without varying profiles. A block of honeycomb, in its compressed form, is mounted on a wedge and run through a bandsaw with the table at an appropriate tilt angle. It is the combination of the wedge angle and the table angle that gives the tapered planform and profile shape. Next the honeycomb is expanded on the shaft and jigged to give the desired angles of attack. With the honeycomb fixed in position, the blade is covered with a fine weave fiberglass cloth. Any surface quality can then be achieved with filling and sanding.