3D Printed Wind Turbine Parts Speed Development, Reduce Costs, and Balance Strength with Weight
Innovative wind turbine uses carbon-filled polymer for strong, lightweight parts with complex geometries intricate features that traditional manufacturing processes can’t achieve.
This wind turbine uses parts made from Ultrafuse® PAHT CF15, one of Forward AM’s many high-performance 3D printing materials. In addition to supplying the material solutions that innovators need, Forward AM helps optimize part designs for additive manufacturing.
Project Breakdown
Industry & Application
Wind Turbines, Clean Energy
Product
Ultrafuse® PAHT CF15
Partner & Technology
BambuLab X1C 3D, Carbon Fiber 3D Printing
Why Forward AM Solutions and Materials?
Forward AM helped with material selection and provided design for manufacturing (DFM) assistance.
Key Numbers
7x increase in iteration speeds, 70% reduction in part costs, 50% less storage space
VentoStream of Bubendorf, Switzerland wants to make a decisive contribution to the environmentally-friendly energy supply of the future. Inspired by turbine-powered aircraft, the Swiss startup has developed a new type of wind turbine called the Tornado that generates significantly more power than conventional, propeller-style units.
In partnership with Forward AM, VentoStream used additive manufacturing to prototype, iterate, and manufacture strong, complex, and lightweight parts quickly and cost-effectively. In addition to supplying Ultrafuse® PAHT CF15, a carbon-fiber filled polymer, Forward AM helped VentoStream to optimize its design for additive manufacturing.
The Challenge
VentoStream needed strong, lightweight parts for its Tornado LSK and DK turbines. The company also needed a quick and cost-effective way to iterate designs and produce replacement parts during field testing. Machining supports the use of carbon fiber, but the turnaround times can be long, the equipment is large and expensive, and subtractive manufacturing creates material waste.
The wind turbine company also needed a manufacturing process that could create complex lattices. Traditional manufacturing can produce simple lattices, but processes like casting and molding can take days or weeks to complete. They also limit design freedom and typically require additional assembly. Plus, there’s tooling to pay for, wait for, and modify when there are design changes.
In addition, VentoStream needed long-lasting parts that could withstand the sun’s ultraviolet (UV) rays and outdoor weather conditions, including precipitation and a range of temperatures. Spinning parts like turbines are also prone to buildups of dust and static electricity. During wind turbine maintenance, electrostatic discharge (ESD) can put technicians at risk.
The Solution
VentoStream used Forward AM’s Ultrafuse® PAHT CF15 to 3D print parts that are both strong and lightweight. This high-performance polyimide contains 15% carbon fiber and resists UV light, aging, outdoor temperatures, and weather. It’s also ESD safe and supports the prototyping and production of complex parts with geometries, such as lattices, that traditional manufacturing can’t achieve.
Unlike machining, casting, or molding, 3D printing doesn’t require expensive investments in large machines that leave an oversized footprint on the factory floor. There’s no tooling to pay for or wait for, and designers can iterate with speed. Print-in-time manufacturing also requires less storage space for part inventories. In addition, 3D printing produces less material waste.
The assistance that VentoStream received wasn’t limited to material selection, however. Importantly, Forward AM helped the wind turbine company fine-tune its use of Ultrafuse® PAHT CF15 for superior print quality with a BambuLab X1C 3D printer. Forward AM also worked with VentoStream to adjust its 3D models for dimensionally-correct parts.
Next Steps
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