Wind turbine rotor blades frequently exceed 80 m in length. Composite materials offer enormous weight savings along with excellent fatigue properties.
The main components of rotor blades are a load-carrying web-spar-structure and an aerodynamic shell. These are typically built by hand using fibre glass reinforced epoxy-based resins. The spar is bending loaded so it has a unidirectional lay-up. The web and shell are designed as a sandwich using balsa wood and foam cores.
Process automation offers great opportunities for quality control and cost reduction.