Next-Generation Wind Turbine Blade Design & Manufacture
The Challenge
A study into the cost drivers of wind-generated power identified a 'sweet spot' in blade length for a cost-optimised turbine solution. Analysis of the existing manufacturing process revealed that the boat-building methodology used to produce current blades was fundamentally unsuitable for blades in excess of 100 metres. A tender was issued to identify alternative design and manufacturing approaches capable of delivering blades beyond that target at commercial scale.
Our Approach
We managed the programme from contract award through to blade delivery, overseeing the engagement with Blade Dynamics as the selected technology partner. We governed the design and manufacture of a test blade and a set of three production blades intended for flight on a test turbine. The programme navigated the rapid growth of the Blade Dynamics business and resolved HSE alignment challenges arising from differences in US and UK regulatory approaches, maintaining delivery momentum throughout.
100m+
Blade length target achieved using carbon fibre sectional manufacture
Higher quality
Sectional carbon fibre construction delivered greater weight uniformity
Delivered
Blade successfully shipped for testing at the OREC blade test facility, UK