ENHANCING WIND TURBINE PERFORMANCE AND SUSTAINABILITY THROUGH 3D-PRINTED BLADE OPTIMIZATION: A STUDY ON MATERIAL AND SHAPE EFFICIENCY

Authors

  • Chun-Kit He † Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.
  • Dawson Wai-Shun Suen † Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.
  • Chi-Ying Vanessa Li Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.
  • Juan Zhang Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.
  • Xuejuan Cui Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.
  • Wei Liu Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.
  • Chi-Wing Tsang Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.
  • Xiao-Ying Lu (Corresponding Author) Department of Construction, Environment & Engineering, Technological and Higher Education Institute of Hong Kong (THEi), Hong Kong 999077, China.

† These authors contributed equally to this work.

Keywords:

3D‑printed blades, Blade geometry, Additive manufacturing, Global warming potential, Wind turbine performance

Abstract

The growing demand for sustainable energy solutions has driven innovation in wind turbine design, particularly in optimizing blade performance and environmental impact. We investigate the application of 3D printing technology to fabricate wind turbine blades, focusing on material selection and geometric design to balance efficiency and sustainability. Two widely used thermoplastics, polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), are evaluated for their environmental footprint using Global Warming Potential (GWP), where PLA exhibits a significantly lower carbon footprint (500g CO₂ eq/kg) compared to ABS (2900g CO₂ eq/kg). The study employs a material extrusion-based 3D printer to produce four blade configurations, combining these materials with distinct shapes, and assesses their power generation efficiency through electrical power, thrust, voltage, and vibration measurements. Our experimental results demonstrate that PLA-based blades not only reduce environmental impact but also achieve competitive performance, suggesting their viability as a sustainable alternative. Furthermore, the flexibility of 3D printing enables rapid prototyping and iterative design improvements, which are critical for advancing wind energy technology. The findings highlight the potential of additive manufacturing to enhance turbine sustainability without compromising functionality, offering a practical pathway for greener energy systems. This work contributes to the broader discourse on renewable energy innovation by bridging material science, manufacturing technology, and environmental considerations.

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Published

2026-04-07

Issue

Vol. 4 No. 2 (2026)

Section

Research Article

DOI:

https://doi.org/10.61784/wjer3088

How to Cite

Chun-Kit He, Dawson Wai-Shun Suen, Chi-Ying Vanessa Li, Juan Zhang, Xuejuan Cui, Wei Liu, Chi-Wing Tsang, Xiao-Ying Lu. Enhancing Wind Turbine Performance And Sustainability Through 3D-Printed Blade Optimization: A Study On Material And Shape Efficiency. World Journal of Engineering Research. 2026, 4(2): 43-51. DOI: https://doi.org/10.61784/wjer3088.