Airfoil support method and apparatus

1. A support for an airfoil, said support comprising:

a trunk and a limb extending from said trunk for distribution within said airfoil;

wherein said limb extends outwardly from said trunk and radially upwardly therefrom at an angle; and

wherein said limb has an opening for eliminating powder left in said airfoil.

2. The support of claim 1 further comprising a strut extending cross-sectionally through said limb and said trunk.

3. The support of claim 1 wherein said angle is about 45°±15°.

4. The support of claim 2 wherein said strut having an opening for eliminating powder left in said airfoil.

5. The support of claim 1 wherein said limb further comprises a plurality of limbs.

6. The support of claim 5 wherein said limbs are offset from each other along a length of said trunk.

7. The support of claim 1 further comprising said airfoil enclosing and attaching to said trunk and said limb.

8. The support of claim 7 wherein said airfoil has an opening at a tip for allowing powder in said airfoil to escape therefrom.

9. The support of claim 7 further comprising a strut attaching to said airfoil, said trunk and said limb.

10. A method for constructing a support for an airfoil, said method comprising:

creating a support having a trunk and a limb extending from said trunk for distribution within said airfoil by using a direct metal manufacturing tool, wherein said airfoil has an opening at a tip for allowing powder in said airfoil to escape therefrom; and

removing powder in said airfoil by tipping said airfoil over.

11. The method of claim 10 further comprising:

creating a 3D model of said trunk and limb.

12. The method of claim 11 further comprising:

creating a build file of said 3D model.

13. The method of claim 12 further comprising:

cross-sectioning said build file of said 3D model and sintering or welding a first layer of said airfoil including said support.

14. The method of claim 13 further comprising:

building a plurality of layers atop said first layer until said airfoil including said support is finished.

15. A method of optimizing a size and shape of a support for an airfoil, said method comprising:

designing a desired shape of an airfoil;

estimating a desired shape for a support having a trunk and a limb extending from said trunk for distribution within said airfoil; and

creating an integral of a Pull/Area ratio for cross-sections of said airfoil and said support within said airfoil.

16. The method of claim 15 further comprising:

determining support strength of said support; and

reforming said desired shape if said support strength does not withstand the integral of said Pull/Area ratio of the airfoil.

17. The method of claim 15 further comprising:

determining support strength of said support; and

reforming said desired shape if said support strength exceeds a minimum required to withstand the integral of said Pull/Area ratio of the airfoil.