Use case
Sustainable wind turbine blade manufacturing
Wind energy is central to Europe’s clean energy transition. However, manufacturing wind turbine blades that are lightweight, durable and recyclable remains a major challenge. Current processes rely on energy-intensive production methods and non-recyclable composites, making it difficult to achieve true sustainability and circularity.
The ORGANIC project applies bio-intelligent additive manufacturing to develop large, high-performance wind turbine blade components that are both recyclable and resource-efficient.
Objectives
The project aims to improve the sustainability and circularity of blade manufacturing by replacing conventional materials with bio-based recyclable composites, optimising structural performance through bio-inspired designs and deploying AI-supported additive manufacturing for precise, first-time-right production. Together, these innovations reduce waste, lower CO₂ emissions and enable a more energy-efficient, environmentally responsible manufacturing process.
Solution
Traditional blade production depends on non-recyclable materials such as PET, PVC and balsa wood, alongside energy-intensive fabrication methods. The ORGANIC project introduces bio-based recyclable composites and bio-inspired lattice designs that improve stiffness, strength and fatigue resistance. These are produced using large-format additive manufacturing equipped with AI-driven monitoring, predictive control and real-time self-correction. This integrated, bio-intelligent approach delivers turbine blades with higher structural efficiency, enhanced recyclability and reduced environmental impact, supporting a more sustainable and circular wind energy industry.
Use case owner
