Standardised pre-forms for high quality and robust joints in wind turbine blade manufacturing
Lead Participant:
DFM BLADES LTD
Abstract
**The Vision**
As offshore wind turbines scale to unprecedented sizes - with blades now exceeding 100 meters - the complexity of manufacturing them grows exponentially. Current assembly methods rely on manual bonding processes that are prone to subtle defects, leading to expensive repairs and potential structural failures in the field.
Our project aims to revolutionise this process by shifting wind turbine manufacturing from reactive quality control to proactive quality assurance.
**Our Technology**
We are developing a new manufacturing framework centred on **pre-fabricated composite components**. Instead of bonding large, variable sections manually, our technology introduces standardised structural "pre-forms" for the critical joints between the shear web and the blade shell.
By utilising **Resin Transfer Moulding (RTM)**, we expect that we can produce modular segments that ensure:
* **Total Consistency:** Eliminating the human error associated with traditional manual lamination.
* **Reduced Costs:** Streamlining the assembly line to reduce production time and material waste.
* **Enhanced Durability:** Creating more robust joints that can withstand the extreme fatigue of offshore environments.
**The Path to Scale**
While the concept has been validated in laboratory trials, the next challenge is industrial scaling. Modern blades require structural reinforcement across 80% of their length. Our current feasibility study focuses on a modular RTM approach, allowing us to manufacture high-performance pre-form segments that can be seamlessly integrated into large blades without the logistical nightmare of transporting oversized parts.
**Why It Matters**
By making blade manufacturing more predictable and efficient, this technology directly supports the global transition to renewable energy. Reducing manufacturing defects lowers the Levelised Cost of Energy (LCOE), making offshore wind more affordable and reliable for everyone.
As offshore wind turbines scale to unprecedented sizes - with blades now exceeding 100 meters - the complexity of manufacturing them grows exponentially. Current assembly methods rely on manual bonding processes that are prone to subtle defects, leading to expensive repairs and potential structural failures in the field.
Our project aims to revolutionise this process by shifting wind turbine manufacturing from reactive quality control to proactive quality assurance.
**Our Technology**
We are developing a new manufacturing framework centred on **pre-fabricated composite components**. Instead of bonding large, variable sections manually, our technology introduces standardised structural "pre-forms" for the critical joints between the shear web and the blade shell.
By utilising **Resin Transfer Moulding (RTM)**, we expect that we can produce modular segments that ensure:
* **Total Consistency:** Eliminating the human error associated with traditional manual lamination.
* **Reduced Costs:** Streamlining the assembly line to reduce production time and material waste.
* **Enhanced Durability:** Creating more robust joints that can withstand the extreme fatigue of offshore environments.
**The Path to Scale**
While the concept has been validated in laboratory trials, the next challenge is industrial scaling. Modern blades require structural reinforcement across 80% of their length. Our current feasibility study focuses on a modular RTM approach, allowing us to manufacture high-performance pre-form segments that can be seamlessly integrated into large blades without the logistical nightmare of transporting oversized parts.
**Why It Matters**
By making blade manufacturing more predictable and efficient, this technology directly supports the global transition to renewable energy. Reducing manufacturing defects lowers the Levelised Cost of Energy (LCOE), making offshore wind more affordable and reliable for everyone.
Lead Participant | Project Cost | Grant Offer |
|---|---|---|
| DFM BLADES LTD | £139,288 | £ 97,502 |
People |
ORCID iD |
| Jelmer Cnossen (Project Manager) |