The AW109 blade arrived with trailing edge delamination, where the bonded composite structure had begun to separate along the trailing edge. Although this type of damage can appear relatively minor externally, it has the potential to affect both structural integrity and aerodynamic performance if left untreated. Following inspection, the blade was approved for repair.
Request a Quote
The damaged composite material was carefully injected with an epoxy adhesive to create a sound structure.
The repair area was then cleaned, profiled and prepared to provide the optimum bonding surface for the composite repair patch.
Proper preparation is one of the most important stages of any helicopter blade repair, directly influencing the long-term strength and durability of the finished repair.
A precision-manufactured composite patch was fitted to the prepared repair area.
Using a controlled vacuum bonding process, the repair patch was cured under carefully monitored temperature and pressure conditions. Vacuum bagging ensures uniform pressure across the repair while eliminating trapped air, producing a high-strength structural bond.
Once the cure cycle was complete, the heat blanket and vacuum equipment were removed.
Following bonding, the repair underwent a tap inspection.
This non-destructive inspection technique allows our technicians to verify the integrity of the bonded repair and identify any hidden disbonds or voids before the blade progresses to finishing.
The inspection confirmed that the repair met the required structural standards.
Once the repair had been approved, the blade was sanded and prepared for painting.
An aviation-approved primer, a conductive coating and further primer was applied before the blade received its final paint finish, restoring both its appearance and protective surface coating against environmental exposure.
Every helicopter blade repair concludes with precision balancing.
Following painting, the AW109 blade underwent balancing to ensure it met the manufacturer's specified tolerances. Balancing weights were adjusted as required before the weight pocket was permanently sealed.
Correct blade balancing is critical for reducing vibration, maintaining rotor system efficiency and extending component life.
After completing the repair, refinishing and balancing processes, the blade underwent a final quality inspection.
The completed AW109 helicopter blade was successfully restored to a serviceable condition and prepared for return to the customer, ready to continue operating safely and efficiently.
Helicopter rotor blades are among the most highly engineered components on any aircraft, requiring specialist knowledge, approved repair procedures and precision workmanship.
At Heliwork, our experienced technicians carry out helicopter blade repairs, composite blade repairs, rotor blade balancing, corrosion repairs and structural restorations to the highest aviation standards.
Whether your blade requires minor damage repair or a complex structural restoration, our workshop has the expertise and facilities to return your components to service with confidence.
No two blades arrive with the same damage, but every repair follows the same proven process.
Every helicopter blade undergoes a detailed inspection to identify structural damage, wear, corrosion, impact damage or other defects that may affect airworthiness.
By accurately assessing the condition of the blade from the outset, we can develop an approved repair plan that restores structural integrity while maintaining compliance with manufacturer and regulatory requirements.
Once the inspection has identified the required work, our technicians repair only the defects present on the blade.
Every repair is completed using approved repair schemes, specialist tooling and controlled workshop processes, ensuring complete traceability and quality throughout every stage of the repair.
At Heliwork, we believe in honest maintenance.
Our philosophy is simple: carry out only the repairs that are necessary. We never increase the repair scope unnecessarily, allowing operators to minimise maintenance costs while ensuring every blade returned from our workshop fully meets the required airworthiness standards.
If you have a helicopter blade requiring inspection, repair or assessment, our team is ready to help.
Whether you're dealing with trailing edge damage, composite repairs, corrosion, impact damage or routine blade maintenance, we'll provide an honest assessment and carry out only the work that's genuinely required.
Get in touch with Heliwork today to discuss your repair or request a no-obligation quotation.
Connect with our experts for tailored maintenance solutions. Ensure your fleet’s performance and safety with trusted, professional support.