R&D specialization showcases modular wind blade prototype

Carbo4Power WTB wind blade prototype. Source | Aimen Technology Centre

As in years past, the Aimen Technology Centre (O Porriño, Spain) is participating as a co-exhibitor at the booth organized by the Spanish Association of Composite Materials (AEMAC), along with 10 other national entities. In addition, some of Aimen’s innovations are prominently displayed at the JEC Innovation Planet, particularly the presentation of its modular wind blade prototype Carbon4Power WTB.

With 58 years of experience serving innovation and industry, Aimen is a national benchmark in R&D and in the provision of technological services in the materials, advanced manufacturing processes, digitization and sustainability fields. It has more than 320 highly qualified professionals and a technological ecosystem that includes advanced laboratories and pilot plants. The organization develops innovative solutions in key sectors such as mobility, aeronautics, energy, metalworking and chemicals.

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Wind: Carbon4Power project

The manufacture of this prototype, developed within the framework of the European Carbo4Power project, represents a milestone for Aimen. “This project demonstrates our ability to lead in the R&D of advanced technologies for renewable energy,” says Jesús Lago, CEO of Aimen. “Our commitment to sustainability and efficiency in the energy sector is reflected in each of the achievements made in the Carbo4Power project, which not only optimizes the manufacturing of wind turbine blades, but also contributes to reducing environmental impact.”

The European Carbo4Power project’s main objective, launched in October 2020, is the development of a new generation of lightweight, high-strength, multifunctional and digitalized materials for the blades of offshore and tidal wind turbines. These advances are intended to improve the operational performance, durability and maintenance intervals of the blades, while reducing the levelized cost of energy and environmental impact.

The Carbon4Power WTB blade prototype integrates novel technologies and materials, such as 3R vitrimeric resins and advanced manufacturing techniques such as infusion and automated fiber placement (AFP). This modular blade, developed at a 1:20 scale, has been based on the geometry of the 15-megawatt IEA turbine blade (120 meters long), selected as a reference blade at the start of the project. The modular design has been divided into three segments with 100% adhesive joints, offering a cost-effective solution, optimizing both manufacturing and operational efficiency.

Within the framework of the project, Aimen has manufactured two wind turbine blade demonstrators with a length of about 6 meters. These prototypes have been successfully validated by mechanical tests at the facilities of one of the project partners, withstanding more than twice the expected load and without defects, both in terms of deformation and visually. The manufacture of these prototypes has been a technical milestone due to the complexity of the design, manufacturing, joining of the components and final assembly, taking into account the rigorous alignment and tolerance requirements necessary in energy sector structures.

Aimen says project results reflect a significant advance in the sustainability and efficiency of wind turbines, with a 25% reduction in waste generated during manufacturing, a 40% reduction in manufacturing costs and a 15% decrease in environmental impact. These improvements not only contribute to the operational efficiency of the turbines, but also address some of the main challenges of the global wind sector, such as logistics, transport of large wind turbines, high maintenance costs and the lack of efficient solutions for recycling blades at the end of their useful life.

Carbo4Power is a project funded by the European Union through the Horizon 2020 program and has a budget of €7.6 million. The consortium is made up of 18 partners from eight different countries that combine technological knowledge and industrial leadership.

Aerospace: CAELESTIS project

In addition to its commitment to the wind energy sector, Aimen is highlighting its role in the development of novel aerospace technologies through the CAELESTIS project. This project, led by Aimen, is developing an end-to-end interoperable simulation ecosystem to perform a multidirectional data flow along the aircraft value chain. Its objective is to accelerate the design and optimization of disruptive aircraft and engine configurations, ensuring their manufacturability from the conceptualization phase.

Aimen is focusing on automated and robotized additive manufacturing of innovative aerospace structures within the framework of this project. The CAELESTIS concept will be validated with the manufacture of a demonstrator based on a new OVG composite concept manufactured by AFP for dry fiber and resin transfer molding (RTM).

Visit Aimen Technology Centre at Booth F135 in Hall 5.