This paper presents a design concept, a modelling methodology and a manufacturing approach for a structural and aerodynamic jet engine blade (vane) made of variable-axial (VA) composite. Based on the boundary conditions of jet engine load scenarios, a composite design of the vane is developed. For the external vane loads, the optimal fibre trajectories within the given design space are calculated. The simulation model used is characterised by a novel modelling approach, supported by the software EDOstructure, for the realistic representation of VA fibre architectures. TFP-related properties are taken into account for the development of the fibre pattern. This fibre is transferred into manufacturing and verifiable prototypes are produced using resin transfer moulding (RTM). During the manufacturing process, the fibre orientation is monitored, digitised and fed back into the simulation model to evaluate the impact of deviations in the manufacturing process on the performance of the structure.