Bravo!!
With the ability to shape this foam as you do, and with such precise repeatability, you could "tune" these blades for various AWS regions.
Oh, to dream....
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"Santa, Roger wants a set of CNC foam cores for Cristmas. Made to max out at 25-35 mph. He's been a good boy most of the time |;>"
"Careful, you'll put your eye out with that! >:-("
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Opp,s sorry. Marketing has gotten to me already. I'm weak. I see it I want it.;_)
Try what works, and try again, until you get a really great blade.
Test the binding agent against a scrap of the foam. A very small test sample will reveal compatability issues. Surely it doesn't cost too much for the raw material. Is machine time an issue?
Don't experimental aircraft builders use I high density version of this same foam, or is that polyurethane? Whichever, I'd say yer well on yer way. If Scaled Composites can put someone into low earth space with similar technology then windturbine blades can be built using similar methods and materials. Cost is another issue. High quality foam, and binders, and fabrics, for aircraft use is probably not cheap, but the glues and technology is proven stuff, and that makes it a tossup deal.
Could you CNC a negative for a split mold of said blade profile? Do you see what I mean? A negative cavity could accept injected foam or fill the preassembled 1/2's of a composite shell/skin. Maybe even allow foam/skin to interactively cure into the form of the blade with the shell in one setp. It seems molding would be faster than milling each core. But I haven't a clue.
Ah, quality material crafted into a higher state of use. The Zen of melting foam.
