Investigation of Short Carbon Fiber-Reinforced Polylactic Acid Composites Blades for Horizontal Axis Wind Turbines: Mechanical Strength and Energy Efficiency of Fused Filament Fabrication-Printed Blades

The use of 3D printing is expanding in manufacturing wind turbine blades for renewable energy. This study examines the relationship between geometric parameters, mechanical strength, and aerodynamic performance in blades made from short carbon fiber-reinforced PLA (SCFR-PLA) composites. To achieve this, it includes a comparative evaluation of innovative blade designs and materials, aiming to enhance both the energy efficiency and mechanical durability of horizontal axis wind turbines (HAWTs). The numerical model of the wind turbine blade is validated against experimental results, which employed a NACA geometry and ABS polymer. Building upon this validation, a design of experiments (DOE) analysis is employed to explore the influence of fused filament fabrication (FFF) parameters on the mechanical properties of SCFR-PLA composites. A novel blade design, referred to as HAWTSav, is numerically evaluated using 3D-printed SCFR-PLA composites. Numerical simulations are conducted to evaluate the energy efficiency and structural integrity of the HAWTSav blade. A comparative analysis is then performed, contrasting the performance of the conventional NACA blade in ABS with the HAWTSav blade in SCFR-PLA composites. The findings highlight the potential of SCFR-PLA composites in the development of efficient and durable wind turbine blades, highlighting their applicability, particularly in small-scale wind energy systems.