Abstract: A system for manufacturing a tower structure of a wind turbine includes an additive printing device having a central frame structure with a platform and an arm member. The arm member is generally parallel to a longitudinal axis of the tower structure. The additive printing device also includes a plurality of robotic arms secured to the arm member of the central frame structure. Each of the robotic arms includes a printer head for additively printing one or more materials. The additive printing device further includes at least one nozzle configured for dispensing a cementitious material. Moreover, the system includes one or more molds additively printed via the additive printing device of a polymer material. As such, the mold(s) define inner and outer wall limits of the tower structure.

Abstract: An additive printing device and a method for using the same to manufacture a tower structure of a wind turbine is provided. The additive printing device includes a vertical support structure, a support ring suspended from the vertical support structure, and a printer head movably coupled to the support ring for selectively depositing cementitious material. A drive mechanism, such as a rack and pinion, moves the printer head around the support ring while selectively depositing cementitious material. The vertical support structure may be raised and/or the relative position between the vertical support structure and the printer head may be adjusted to raise the printer head to print subsequent layers. This process may be repeated to print the tower structure layer-by-layer from the ground up.

Abstract: A method of joining first and second blade components of a rotor blade of a wind turbine includes providing corresponding first and second positioning elements at an interface of the first and second blade components. The method also includes aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together. Further, the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components. Moreover, the method includes permanently securing the first and second blade components together such that the desired spacing is maintained between the first and second blade components.

Abstract: A method of joining first and second blade components of a rotor blade of a wind turbine includes providing corresponding first and second positioning elements at an interface of the first and second blade components. The method also includes aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together. Further, the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components. Moreover, the method includes permanently securing the first and second blade components together such that the desired spacing is maintained between the first and second blade components.

Abstract: A method for repairing or improving a lightning protection system of a rotor blade of a wind turbine having a blade root and a blade tip includes identifying a repair or improvement location in the lightning protection system of the rotor blade. The method includes removing one or more layers of material at the repair or improvement location that form part of a shell of the rotor blade so as to expose existing conductive material in the rotor blade. The method also includes placing a conductive layer of material atop the repair or improvement location such that a root-side edge of the conductive layer overlaps the existing conductive material. Moreover, the method includes electrically connecting the root-side edge of the conductive layer with the existing conductive material and a tip-side edge of the conductive layer of material with the blade tip. The method further includes covering the conductive layer with an outer covering.

Abstract: A system for forming an article includes a polymer resin formulation formed of a semicrystalline polymer material having a first fiber content and an amorphous polymer material having a second fiber content. The first fiber content is higher than the second fiber content. Further, the semicrystalline and amorphous polymer materials are blended together to form the polymer resin formulation having a blended fiber content of greater than 10% by weight. Moreover, the polymer resin formulation is amorphous. The system also includes a computer numeric control (CNC) device for printing and depositing the polymer resin formulation layer by layer to form the article.

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 printheads 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 printheads is moveable along the first axis, the second axis, or both. At least one of the printheads of the plurality of printheads is moveable independently of one another along a third axis.

Abstract: In an aspect, the present disclosure is directed to a composite structure. The composite structure includes a three-dimensional (3-D) grid structure and at least one monolithic skin layer at least partially enveloping and securing the grid structure. As such, the grid structure is configured to stabilize the composite structure under at least one of: static local buckling and dynamic global buckling.

Abstract: A method for manufacturing an outer skin of a rotor blade includes forming an outer skin layer of the outer skin from a first combination of at least one of one or more resins or fiber materials. The method also includes forming an inner skin layer of the outer skin from a second combination of at least one of one or more resins or fiber materials. More specifically, the first and second combinations are different. Further, the method includes arranging the outer and inner skin layers together in a stacked configuration. In addition, the method includes joining the outer and inner skin layers together to form the outer skin.

Abstract: A system for manufacturing a blade component of a rotor blade of a wind turbine includes a blade mold of the rotor blade, at least one blade skin arranged atop the blade mold, and a computer numeric control (CNC) device comprising a printer head and a scanning device. The printer head is configured for printing and depositing a material onto the at least one blade skin to form the blade component. The scanning device includes a processor and a scanner communicatively coupled to the processor.

Abstract: A method of joining first and second blade components of a rotor blade of a wind turbine includes providing corresponding first and second positioning elements at an interface of the first and second blade components. The method also includes aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together. Further, the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components. Moreover, the method includes permanently securing the first and second blade components together such that the desired spacing is maintained between the first and second blade components.

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: Methods of manufacturing a cementitious structure, such as a structure for supporting a wind turbine, include additively printing, via an additive printing device, one or more contours that include a cementitious material so as to form a cementitious structure in a layer by layer manner such that a first portion of the plurality of contours comprises a first plurality of contour coupling features that engage with a second plurality of contour coupling features of a second portion of the plurality of contours.

Abstract: A system for manufacturing a panel includes a forming assembly having opposing press plates and at least one platen assembly arranged between the opposing press plates. The platen assembly includes first and second platens connected together via at least one elastic deformable member. Further, the forming assembly is operable in a heating mode and a cooling mode. Moreover, the first platen is maintained at a predetermined temperature range during each of the heating and cooling modes. During the heating mode, the elastic deformable member(s) is compressed such that the first and second platens contact each other. As such, one or more layers of material to be consolidated are held by the forming assembly as the forming assembly applies heat and pressure to the layer(s), thereby consolidating the panel.

Abstract: A system for manufacturing a panel includes a support frame, a first caul plate arranged atop the support frame, a second caul plate arranged atop the first caul plate, and a heating assembly having a housing defining an inlet and an outlet. The housing includes one or more heaters. The heater(s) is configured to generate heat and the housing is configured to generate a first pressurized gas film. Thus, one or more layers of material to be consolidated may be placed between the first and second caul plates and drawn through the heating assembly as the heating assembly applies pressure to the one or more layers of material to be consolidated via the first pressurized gas film in combination with applying the heat via the one or more heaters, thereby consolidating the panel.

Abstract: A method for forming an article includes placing at least one forming tool of the article adjacent to a substrate, the at least one forming tool having a predefined shape and/or height. The method also includes extruding a bead of material from a printer head of a print head assembly directly into or onto the forming tool(s) of the article so as to increase a height of the bead of material via the forming tool(s), thereby reducing or eliminating a number of extruded layers of the material. Further, the method includes allowing the material to solidify to form the article. Thus, by using the forming tool(s), multiple printed layers of the material can be eliminated or reduced.

Abstract: A system for forming an article includes at least one print head assembly comprising a printer head, a printer nozzle, and at least one hopper. The system also includes a drying assembly having at least one dryer and a dispenser. The dryer is for drying a plurality of polymer pellets of one or more polymer resin formulations. The dispenser is positioned above and separate from the print head assembly for dispensing the dried plurality of pellets directly from the drying assembly and into the hopper of the print head assembly before or during printing. Further, the printer head is configured to melt the dried plurality of polymer pellets. The printer nozzle is configured for depositing and printing the melted plurality of polymer pellets onto a substrate to form the article. The system also includes a controller for controlling and automating the system.

Abstract: A modular extrusion system for forming an article includes a support frame and a plurality of print head modules removably connected to the support frame. Each of the print head modules includes a printer head, a printer nozzle, a hopper, and an integrated control module. The hoppers are configured for holding a plurality of polymer pellets. The printer heads of the plurality of print head modules each include a body defining a barrel, a rotating extrusion screw extending through the barrel, and one or more heaters at least partially surrounding the barrel for melting the plurality of polymer pellets into a polymer resin formulation. The printer nozzles are configured for printing and depositing the polymer resin formulation onto a substrate to form the article. The modular extrusion system also includes a control system communicatively coupled to each of the integrated control modules for controlling the modular extrusion system.

Abstract: The present disclosure is directed to a method for creating a vacuum forming mold assembly. The method includes forming a plurality of support plates. Each support plate includes a surface defining a shape corresponding to a cross-section of at least a portion of the mold cavity. The method also includes removably coupling a mold body to the plurality of support plates to form the mold assembly. The mold body conforms to the shape of the surface of each support plate after being removably coupled to the plurality of support plates such that the mold body defines at least a portion of a mold cavity of the mold assembly. The mold body defines at least one of one or more vacuum manifolds or one or more fluid passages.

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.