Design, Fabrication, Testing of a New Affordable Main Rotor Blade for the AH-64D Apache Helicopter

A new composite main rotor blade was developed for the AH64D Apache helicopter and was first flown in November 2003. Boeing Mesa developed this blade to replace the current metal blade with one that would be affordable in terms of acquisition and operations and support (O & S) costs, and would also provide increased performance to accommodate future heavier versions of the aircraft. A design evolved that is simple to build, and is not only affordable but also meets its performance goals. The results of the ballistic testing, structural testing and flight-testing did not disappoint. However, they indicated that some areas would require changes for the production design.