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Rapid Prototyping of Wind Turbine Blades

This document summarizes research into 3D printing small wind turbine blades for testing. The objectives were to develop a design and manufacturing method to rapidly prototype blades. A program was used to design blades according to input parameters. The blades were then 3D printed and various reinforcement methods were investigated, including pouring a filler material, infusing short fibers, adding pultruded rods, and inserting threaded rods. Testing of printed blades showed they worked well for practical testing, and additive manufacturing can help with composite prototyping. Future work includes improving accuracy, long-term testing, strength testing, and larger scale printing.

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68 views28 pages

Rapid Prototyping of Wind Turbine Blades

This document summarizes research into 3D printing small wind turbine blades for testing. The objectives were to develop a design and manufacturing method to rapidly prototype blades. A program was used to design blades according to input parameters. The blades were then 3D printed and various reinforcement methods were investigated, including pouring a filler material, infusing short fibers, adding pultruded rods, and inserting threaded rods. Testing of printed blades showed they worked well for practical testing, and additive manufacturing can help with composite prototyping. Future work includes improving accuracy, long-term testing, strength testing, and larger scale printing.

Uploaded by

afshin dadvar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Rapid Prototyping (3D Printing) of Small

Wind Turbine Blades

Small Wind Turbines 2016, Vienna


Sean Poole, Russell Phillips
Introduction

Objective: To develop a design and manufacturing


method to rapidly prototype small wind turbine
blades for practical testing.

BLADE DESIGN

DEVELOP CAD

PROCESS CAM

3D PRINT BLADE

REINFORCE PRINTED BLADE


Blade Design

Using BEM theory, a


programme was written
in Labview to design a
turbine blade according
to parameter inputs.
Blade Design
Develop CAD
Process CAM

G-code for 3D printer generated using Repetier-Host


3D Print Blades

Print the turbine blades


(and make a 3D printer)
Reinforce Printed
Blade

4 reinforcement methods
investigated:

1. Pour filled
2. Short fibre infused
3. Pultruded rod reinforced
4. Threaded rod reinforced
Reinforce Printed
Blade

1. Pour Filled
Reinforce Printed
Blade

1. Pour Filled
Advantages:
1. Fast spiral printing (6-12 hours/blade)
2. Saves print material (hollow)
3. Strong print (easily controlled pass rate)
4. Quick reinforcement (mix and pour)
5. Shell could be removed
Reinforce Printed
Blade

1. Pour Filled
Disadvantages:
1. Flatter surfaces warping during printing
2. Exo-therm risk for larger volumes
3. Cracking of shell during water cooling
causes water inside bade
4. Weakest of the processes
5. Unbalancing between blades
Reinforce Printed
Blade

2. Short fibre infused


Reinforce Printed
Blade

2. Short fibre infused


Advantages:
1. Fast spiral printing (6-12 hours/blade)
2. Saves print material (hollow)
3. Strong print (easily controlled pass rate)
4. Strong reinforcement
5. Multidirectional reinforcement
6. Shell could be removed
Reinforce Printed
Blade

2. Short fibre infused


Disadvantages:
1. Flatter surfaces warping during printing
2. Thermal exo-therm risk for larger volumes
3. Fibre displacement during infusion
4. Lack of control of fibre direction
5. Lack of control of fibre density
6. Lack of control of fibre distribution
7. Lack of control of blade volume during infusion
8. Unbalancing between blades
Reinforce Printed
Blade

3. Pultruded rod reinforced


Reinforce Printed
Blade

3. Pultruded rod reinforced


Advantages:
1. Good geometry accuracy (no shell warping)
2. Light weight
3. Very strong blade length strength
4. No exo-therm problems
Effects and
Benefits of
Optimization

3. Pultruded rod reinforced


Disadvantages:
1. Complicated printing (pultruded rods inside
matrix from root to tip)
2. Long print times (12-24 hours)
3. Delicate shell (no reinforcement of profile)
4. Unbalancing between blades
Reinforce Printed
Blade

4. Threaded rod reinforced


Reinforce Printed
Blade

4. Threaded rod reinforced


Advantages:
1. Good geometry accuracy (no shell warping)
2. Light weight
3. Fairly strong blade length strength
4. No exo-therm problems
5. Quick assembly
6. Little manufacturing risk
7. Well balanced
Effects and
Benefits of
Optimization

4. Threaded rod reinforced


Disadvantages:
1. Long print times (12-24 hours)
2. Delicate shell (no reinforcement of profile)
3. CAD model needs to be updated to allow
threaded shaft to be inserted
ORF -
Outdoor Research
Facility

Testing = Happiness
Disaster

Monday - 21 September 2015


Blade Printing

Tuesday –
22 September 2015
New Blade Set – 7
days later

Monday - 28 September 2015


Conclusions and
Future Work

Conclusion:
• Blades work well for practical testing.
• Additive manufacturing can assist with
rapid prototype composite
manufacturing.
• Future work required to make process
more repetitively accurate (geometry
and weight distribution).
• Long term testing required.
• Strength testing required.
• Large (4.5 m ) mould printing.
Current Work –
Larger Machines

Build Size: 1.5 m X 1.5 m X 5.0 m


Current Work -
Plug
Manufacturing
Questions?

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