Posters

Abstract

Wind energy is a key component of the UK’s renewable energy strategy. As demand for sustainable electricity increases, wind power offers a reliable path toward cleaner energy generation. A critical element in turbine design is the blade; however, models optimized for large-scale turbines do not directly apply to micro- or small-scale systems, where performance is strongly influenced by the Reynolds number. To do so, different designs need to be explored to maximize the power coefficient. In this context, 3D printing has emerged as a promising fabrication method. It enables customizable blade geometries, minimizes material waste through layer-by-layer construction. It further allows the on-site production of small, modular turbines using inexpensive filament materials with minimal tooling, while offering the flexibility to create lightweight blades with tailored internal structures. This research investigates how the internal structure of 3D-printed turbine blades affects performance, focusing on variations in infill density. Infill density directly influences blade weight and mechanical properties such as strength, flexibility, and impact resistance. Turbine blades with four honeycomb infill levels (5%, 30%, 60%, and 100%) are tested while keeping other design parameters constant. Blade performance is evaluated under different loading conditions to measure wind power output, and compressive strength tests are conducted to assess structural integrity and strength-to-weight ratios. The findings aim to identify infill configurations that achieve an optimal balance between wind energy output and structural efficiency. Such insights can guide the designers of micro or small-scale, 3D-printed turbine blades, highlight how additive manufacturing can advance low-cost, adaptable renewable energy solutions.