Technology Integration through Additive Manufacturing of Wind Turbine Blade Tips

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.