This study aims to design and analyze the performance of the helicopter rotor blades of the Sikorsky SH-3 helicopter. It is also looking to improve the durability and performance of the rotor blades whilst maintaining its structural capabilities. Finite element analysis (FEA) and computational fluid dynamics (CFD) were applied to simulate the structural integrity and aerodynamic performance of steel and composite-designed rotor blades. The result of this optimization would increase the efficiency and longevity of the rotor blades. The cost of the optimized rotor blade will also be considered. A new composite main rotor has been selected for rotor blades that produce considerable improvement in hover and translational flight performance. The comparative assessment showed a significant increase in hover lift and a considerable improvement in flight level performance compared to the old steel blades. An increase in hover lift capability (810 kg) could be expected. Neither change in component lifetimes, nor modifications to the SH-3 helicopter are required to use the new blades. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2025.