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Technology Integration through Additive Manufacturing of Wind Turbine Blade Tips
  • +15
  • Brent C. Houchens,
  • Evan Sproul,
  • Jonathan Berg,
  • Paolo G. Caserta,
  • Miguel H. Hernandez,
  • Daniel Houck,
  • Helio Lopez,
  • David Maniaci,
  • Graham Monroe,
  • Joshua Paquette,
  • Sal Rodriguez,
  • Julia N. Tilles,
  • Nathaniel deVelder,
  • Michelle Williams,
  • Carsten H. Westergaard,
  • Trey McIntosh,
  • James A. Payant,
  • Kyle K. Wetzel
Brent C. Houchens
Sandia National Laboratories

Corresponding Author:brent.houchens@sandia.gov

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Evan Sproul
Sandia National Laboratories
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Jonathan Berg
Sandia National Laboratories
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Paolo G. Caserta
Sandia National Laboratories
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Miguel H. Hernandez
Sandia National Laboratories
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Daniel Houck
Sandia National Laboratories
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Helio Lopez
Sandia National Laboratories
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David Maniaci
Sandia National Laboratories
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Graham Monroe
Sandia National Laboratories
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Joshua Paquette
Sandia National Laboratories
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Sal Rodriguez
Sandia National Laboratories
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Julia N. Tilles
Sandia National Laboratories
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Nathaniel deVelder
Sandia National Laboratories
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Michelle Williams
Sandia National Laboratories
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Carsten H. Westergaard
Sandia National Laboratories
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Trey McIntosh
Stratasys Ltd
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James A. Payant
Wetzel Wind Energy Services
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Kyle K. Wetzel
Wetzel Wind Energy Services
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Abstract

The Additively-Manufactured, System-Integrated Tip (AMSIT) project is leveraging the flexibility of 3D printing to integrate several technologies in a wind turbine blade tip, while reducing the levelized cost of electricity (LCOE) produced. The design integration is demonstrated for a 200 kilowatt-scale turbine with 13-meter blades, with the outer 15% of the blade replaced with a 3D-printed design. Aerodynamic performance is enhanced through inclusion of a winglet and surface texturing, both challenging for traditional manufacturing. Longevity and durability is improved through integrated lightning and leading edge erosion protection. Increased power, reduced repair frequency, and ease of repair through blade modularity all contribute to reduced LCOE. Cost models are are extended to modern megawatt-scale designs to estimate the impact of the technology at scale, demonstrating the potential to reduce LCOE very significantly for modern onshore turbines, with even higher potential savings offshore.
14 Nov 2023Submitted to Wind Energy
14 Nov 2023Submission Checks Completed
14 Nov 2023Assigned to Editor
14 Nov 2023Review(s) Completed, Editorial Evaluation Pending
14 Nov 2023Reviewer(s) Assigned
11 May 20241st Revision Received
11 May 2024Submission Checks Completed
11 May 2024Assigned to Editor
11 May 2024Review(s) Completed, Editorial Evaluation Pending
11 May 2024Reviewer(s) Assigned
01 Jul 2024Editorial Decision: Revise Minor
08 Aug 20242nd Revision Received
11 Aug 2024Assigned to Editor
11 Aug 2024Submission Checks Completed
11 Aug 2024Review(s) Completed, Editorial Evaluation Pending
12 Aug 2024Editorial Decision: Accept