3D printed rotor blades for a research wind turbine: Aerodynamic and structural design and testing

Abstract

This study combines the design, the 3D printing and the testing of a small 3-bladed wind turbine rotor for research and teaching purposes. The objective is the additive manufacturing of a rotor with a radius of one meter, as an alternative to subtractive methods, such as computerized milling. The blade design is developed using freely available software packages. The aerodynamic considerations include the airfoil selection, the calculation of the blade geometry and the simulation of the ultimate load cases. The structural considerations are focussed on the printable materials, the infill structures and the retrofit of a load-carrying spar. The rotor blades are 3D printed with the BigRep One at the maker space of the TH Wildau. The structural integrity of the prototype blade is tested in terms of the ultimate root bending moments and the centrifugal forces at the HTW Berlin. The aerodynamic run-up tests are performed at the large wind tunnel of the TU Berlin measuring the power curves. The successful prototype paves the way for follow-up projects, such as open field tests and the 3D printing of larger rotor blades.