BAAM Additive Manufacturing of Magnetically Levitated Wind Turbine

2018 ◽  
Author(s):  
Bradley S. Richardson ◽  
Mark W. Noakes ◽  
Alex C. Roschli
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Magnetically Levitated

scholarly journals Large-Scale Additive Manufacturing for Low Cost Small-Scale Wind Turbine Manufacturing

2020 ◽  
Author(s):  
Brian Post ◽  
Phillip Chesser ◽  
Alex Roschli ◽  
Lonnie Love ◽  
Katherine Gaul
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Large Scale ◽  
Low Cost ◽  
Small Scale

Hybrid Polymer Additive Manufacturing of a Darrieus Type Vertical Axis Wind Turbine Design to Improve Power Generation Efficiency

2016 ◽  
Author(s):  
Sourabh Deshpande ◽  
Nithin Rao ◽  
Nitin Pradhan ◽  
John L. Irwin
Keyword(s):  
Power Generation ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Wind Turbine ◽  
Turbine Blades ◽  
Vertical Axis ◽  
Blade Design ◽  
Vertical Axis Wind Turbine ◽  
Wind Turbine Blades ◽  
3D Printed

Utilizing the advantages of additive manufacturing methods, redesigning, building and testing of an existing integral Savonius / Darrieus “Lenz2 Wing” style vertical axis wind turbine is predicted to improve power generation efficiency. The current wind turbine blades and supports made from aluminum plate and sheet are limiting the power generation due to the overall weight. The new design is predicted to increase power generation when compared to the current design due to the lightweight spiral Darrieus shaped hollow blade made possible by 3D printing, along with an internal Savonius blade made from aluminum sheet and traditional manufacturing techniques. The design constraints include 3D printing the turbine blades in a 0.4 × 0.4 × 0.3 m work envelope while using a Stratasys Fortus 400mc and thus the wind turbine blades are split into multiple parts with dovetail joint features, when bonded together result in a 1.2 m tall working prototype. Appropriate allowance in the mating dovetail joints are considered to facilitate the fit and bonding, as well as angle, size and placement of the dovetail to maximize strength. The spiral shape and Darrieus style cross section of the blade that provides the required lift enabling it to rotate from the static condition are oriented laterally for 3D printing to maximize strength. The bonding of the dovetail joints is carried out effectively using an acetone solution dip. The auxiliary components of the wind turbine which include the center support pole, top and bottom support, and center Savonius blades are manufactured using lightweight aluminum. Design features are included in the 3D printed blade parts so that they can be assembled with the aluminum parts in bolted connections. Analysis of the 3D CAD models show that the hybrid aluminum and hollow 3D printed blade construction provides a 50% cost savings over a 3D printed fully solid blade design while minimizing weight and maximizing the strength where necessary. Analysis of the redesign includes a detailed weight comparison, structural strength and the cost of production. Results include linear static finite element analysis for the strength in dovetail joint bonding and the aluminum to 3D printed connections. Additional data reported are the time frame for the design and manufacturing of the system, budget, and an operational analysis of the wind turbine with concern for safety. Results are analyzed to determine the advantages in utilizing a hybrid additive manufacturing and aluminum construction for producing a more efficient vertical axis wind turbine. Techniques used in the production of this type of wind turbine blade are planned to be utilized in similar applications such as a lightweight hovercraft propeller blade design to be tested in future research projects.

Powder-Binder Jetting Large-Scale, Metal Direct-Drive Generators: Selecting the Powder, Binder, and Process Parameters

2019 ◽  
Author(s):  
Austin C. Hayes ◽  
Gregory L. Whiting
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Large Scale ◽  
Material Selection ◽  
Direct Drive ◽  
Turbine Generators ◽  
Wind Turbine Generators ◽  
Complex Parts ◽  
Printing Parameters ◽  
Binder Jetting

Abstract Additive manufacturing enables the production of complex geometries extremely difficult to create with conventional subtractive methods. While good at producing complex parts, its limitations can be seen through its penetration into everyday manufacturing markets. Throughput limitations, poor surface roughness, limited material selection, and repeatability concerns hinder additive manufacturing from revolutionizing all but the low-volume, high-value markets. This work characterizes combining powder-binder jetting with traditional casting techniques to create large, complex metal parts. Specifically, we extend this technology to wind turbine generators and provide initial feasibility of producing complex direct-drive generator rotor and stator designs. In this process, thermal inkjet printer heads selectively deposit binder on hydroperm casting powder. This powder is selectively solidified and baked to remove moisture before being cast through traditional methods. This work identifies a scalable manufacturing process to print large-scale wind turbine direct drive generators. As direct-drive generators are substantially larger than their synchronous counterparts, a printing process must be able to be scaled for a 2–5 MW 2–6m machine. For this study, research on the powder, binder, and printing parameters is conducted and evaluated for scalability.

Recycling of fiberglass wind turbine blades into reinforced filaments for use in Additive Manufacturing

2019 ◽  
Vol 175 ◽  
pp. 107101 ◽  
Author(s):  
Amirmohammad Rahimizadeh ◽  
Jordan Kalman ◽  
Kazem Fayazbakhsh ◽  
Larry Lessard
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Turbine Blades ◽  
Wind Turbine Blades

scholarly journals Additive Manufacturing of Wind Turbine Molds

2017 ◽  
Author(s):  
Brian Post ◽  
Bradley Richardson ◽  
Peter Lloyd ◽  
Lonnie Love ◽  
Stephen Nolet ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine
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