Exploration of bioinspired small wind turbine blade manufacturing alternatives: Defining materials and processes

Abstract

In the domain of Horizontal Wind Turbines, the key role of blade material and process selection is discussed. Existing methodologies and manual manufacturing processes, while addressing this issue, suffer from complexity and environmental drawbacks. To mitigate these issues, the study introduces a comprehensive methodology for the selection, implementation, testing and analysis of materials and processes for small blade construction, taking into account various constraints. The research conducts a thorough exploration of manufacturing processes, considering factors such as time, affordability, machine accessibility, repeatability, elements to be manufactured, and adaptability to complex surfaces. A systematic comparison of materials and processes, along with proposed filtering methods, reveals that rotomolding/polyurethane casting exhibits superior performance due to improved energy capture and inertia. The study underscores the importance of careful material and process selection to optimize blade efficiency and highlights the need for further research to address mechanical, economic, environmental, scalability, and material advancement challenges.