Abstract: A method for manufacturing a rotor blade component of a rotor blade includes feeding a flat sheet of material into a thermoforming system, wherein the material comprises at least one of a thermoplastic or thermoset material. The method also includes heating the flat sheet of material via the thermoforming system. Further, the method includes shaping the heated flat sheet of material via at least one roller of the thermoforming system into a desired curved shape. Moreover, the method includes dispensing the shaped sheet of material from the thermoforming system. In addition, the method includes cooling the shaped sheet of material to form the rotor blade component.

Abstract: The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis.

Abstract: Rotor blade panels, along with methods of their formation, are provided. The rotor blade panel may include one or more fiber-reinforced outer skins having an inner surface; and, a plurality of reinforcement structures on the inner surface of the one or more fiber-reinforced outer skins, where the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited. The reinforcement structure includes, at least, a first composition and a second composition, with the first composition being different than the second composition.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof. In one embodiment, the method includes forming an outer surface of a rotor blade panel from one or more fiber-reinforced outer skins. The method also includes printing and depositing at least one reinforcement structure onto an inner surface of the one or more fiber-reinforced outer skins to form the rotor blade panel, wherein the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited.

Abstract: Rotor blade panels, along with methods of their formation, are provided. The rotor blade panel may include one or more fiber-reinforced outer skins having an inner surface; and, a plurality of reinforcement structures on the inner surface of the one or more fiber-reinforced outer skins, where the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited. The reinforcement structure includes, at least, a first composition and a second composition, with the first composition being different than the second composition.

Abstract: The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof. In one embodiment, the method includes forming an outer surface of a rotor blade panel from one or more fiber-reinforced outer skins. The method also includes printing and depositing at least one reinforcement structure onto an inner surface of the one or more fiber-reinforced outer skins to form the rotor blade panel, wherein the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited.

Abstract: The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis.

Abstract: The present disclosure is directed to a method of manufacturing a rotor blade component of a wind turbine is disclosed. The method includes placing at least one first pultruded member into a curved rotor blade component mold. More specifically, the first pultruded member includes at least one design characteristic configured to allow the first pultruded member to sit substantially flush against an inner surface of the curved rotor blade component mold. The method also includes placing at least one second pultruded member atop the at least one first pultruded member and infusing the first and second pultruded members together to form the rotor blade component.

Abstract: A rotor blade segment of a wind turbine includes a seamless leading edge surface. A method of manufacturing a rotor blade segment of a wind turbine, the rotor blade segment having a seamless leading edge surface, includes forming an outer skin of the rotor blade segment. The outer skin defines a continuous outer surface. The continuous outer surface includes a pressure side surface extending between a pressure side aft edge and a pressure side forward edge, a suction side surface extending between a suction side forward edge and a suction side aft edge, and the seamless leading edge surface extends between the pressure side forward edge and the suction side forward edge. After folding the outer skin, the pressure side surface is positioned opposite the suction side surface and the pressure side aft edge is proximate the suction side aft edge.

Abstract: A method for manufacturing a rotor blade panel of a wind turbine includes placing one or more fiber-reinforced outer skins into a mold of the rotor blade panel. The method also includes printing and depositing, via a computer numeric control (CNC) device, a plurality of rib members that form at least one three-dimensional (3-D) reinforcement grid structure onto an inner surface of the one or more fiber-reinforced outer skins. Further, the grid structure bonds to the one or more fiber-reinforced outer skins as the grid structure is deposited. Moreover, the method includes printing at least one additional feature into the grid structure.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof, e.g. using 3D printing. In one embodiment, the method includes forming a rotor blade structure having a first surface and an opposing, second surface, the first and second surfaces being substantially flat. Another step includes printing a leading edge segment of the rotor blade onto the first surface, wherein heat from the printing bonds the leading edge segment to the first surface. The method also includes rotating the rotor blade structure having the leading edge segment attached thereto. A further step includes printing a trailing edge segment of the rotor blade onto the second surface, wherein heat from the printing bonds the trailing edge segment to the second surface. Another step includes securing one or more fiber-reinforced outer skins to the leading and trailing edge segments so as to complete the rotor blade.

Abstract: The present disclosure is directed to an apparatus and method for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis. A second frame assembly is moveable above the mold along the first axis, the second axis, or both. The second frame assembly includes a holding device. The holding device affixes to and releases from an outer skin to place and displace the outer skin at the mold.

Abstract: The present disclosure is directed to a rotor blade that includes a shell defining an interior cavity. The rotor blade also includes exterior surfaces defining a pressure side, a suction side, a leading edge, and a trailing edge. Each of the pressure side, the suction side, the leading edge, and the trailing edge extends between a tip and a root. The shell defines a span and a chord. A shear web is positioned in the interior cavity and coupled to the shell. The shear web includes a lattice structure.

Abstract: Wind turbine rotor blade components including pultruded rods and methods of manufacturing the same are disclosed. More specifically, the rotor blade component includes a plurality of pultruded rods housed within an enclosed primary outer casing. The enclosed primary outer casing includes a hollow interior, a root end, and an opposing tip. As such, each of the plurality of pultruded rods is received within the enclosed primary outer casing and secured therein via a first resin material. Further, an arrangement of the plurality of pultruded rods within the primary outer casing and a relationship of a maximum dimension of each of the plurality of pultruded rods and a maximum dimension of the enclosed primary outer casing are configured to maximize flexibility of the rotor blade component.

Abstract: The present subject matter is directed to methods for manufacturing rotor blades and/or components thereof of a wind turbine. In one embodiment, the method includes forming the rotor blade component and covering at least a portion of the rotor blade component with at least one coating material. In addition, the coating material includes at least one additive having a changeable pigment. After the component is formed, the method includes inspecting the rotor blade component for defects. After inspection, the method further includes activating the additive to change the pigment from a transparent finish to a colored finish.

Abstract: The present disclosure is directed to a rotor blade assembly for a wind turbine having a first rotor blade segment with a first spar cap segment and a second rotor blade segment with a second spar cap segment. The first and second spar cap segments are arranged together at an interface and are constructed of a composite material. Further, the rotor blade assembly includes a joint assembly at the interface of the first and second spar cap segments. The joint assembly is constructed of a first metal joint secured to the first spar cap segment and a second metal joint secured to second spar cap segment. Moreover, the first and second metal joints are welded together at a weld area.

Abstract: A method for manufacturing a rotor blade component of a rotor blade includes feeding a flat sheet of material into a thermoforming system, wherein the material comprises at least one of a thermoplastic or thermoset material. The method also includes heating the flat sheet of material via the thermoforming system. Further, the method includes shaping the heated flat sheet of material via at least one roller of the thermoforming system into a desired curved shape. Moreover, the method includes dispensing the shaped sheet of material from the thermoforming system. In addition, the method includes cooling the shaped sheet of material to form the rotor blade component.

Abstract: A rotor blade segment of a wind turbine includes a seamless leading edge surface. A method of manufacturing a rotor blade segment of a wind turbine, the rotor blade segment having a seamless leading edge surface, includes forming an outer skin of the rotor blade segment. The outer skin defines a continuous outer surface. The continuous outer surface includes a pressure side surface extending between a pressure side aft edge and a pressure side forward edge, a suction side surface extending between a suction side forward edge and a suction side aft edge, and the seamless leading edge surface extends between the pressure side forward edge and the suction side forward edge. After folding the outer skin, the pressure side surface is positioned opposite the suction side surface and the pressure side aft edge is proximate the suction side aft edge.

Abstract: A method for manufacturing a rotor blade panel of a wind turbine includes placing one or more fiber-reinforced outer skins into a mold of the rotor blade panel. The method also includes printing and depositing, via a computer numeric control (CNC) device, a plurality of rib members that form at least one three-dimensional (3-D) reinforcement grid structure onto an inner surface of the one or more fiber-reinforced outer skins. Further, the grid structure bonds to the one or more fiber-reinforced outer skins as the grid structure is deposited. Moreover, the method includes printing at least one additional feature into the grid structure.