<p>Vertical-axis wind turbines have attracted resurged interest across various levels, driven by inherent advantages such as omnidirectional wind acceptance, low acoustic emissions, reduced maintenance requirements, and suitability for deployment in urban environments. Central to their structural and aerodynamic performance is the blade—a critical component subjected to multifaceted loading conditions including centrifugal, gravitational, and aerodynamic forces. These combined loads accelerate fatigue and fracture, highlighting the need for both optimised design and high-precision manufacturing processes. This paper presents a critical review of the existing literature, with a dual focus on blade design and manufacturing. In terms of design, particular attention is given to finite element studies, including underlying assumptions, methodologies, and the principal insights. From the manufacturing perspective, current blade fabrication techniques are assessed for their ability to satisfy structural, geometric, and material performance requirements imposed by design specifications. The discussion emphasises how design and manufacturing constraints influence the blade durability, quality, and scalability. By synthesising insights from both domains, the paper identifies significant research gaps—particularly at the interface between simulation reliability and manufacturing efficacy. The paper ultimately concludes with proposing strategies and pathways to support the design and manufacture of more robust, efficient, and viable blades for the future.</p>