Innovative circular materials and design methods for the development of Floating Wind Turbine components for offshore Wind Farms of the future

Project Information

MADE4WIND

Grant agreement ID: 101136096

DOI

10.3030/101136096

EC signature date 31 October 2023

Start date 1 December 2023

End date 31 May 2027

Funded under

• Climate, Energy and Mobility

Total cost

€ 6 003 276,25

EU contribution

€ 6 003 276,25

Coordinated by

SINTEF AS
Norway

Periodic Reporting for period 1 - MADE4WIND (Innovative circular materials and design methods for the development of Floating Wind Turbine components for offshore Wind Farms of the future)

Reporting period: 2023-12-01 to 2025-05-31

Summary of the context and overall objectives of the project

Context and Overall Objectives
Europe’s goal of climate neutrality by 2050 requires rapid expansion of renewable energy, with floating offshore wind turbines (FWTs) offering a scalable solution due to higher offshore wind and minimal land use. However, current FWT technologies face challenges in cost, reliability, sustainability, and environmental impact.

MADE4WIND addresses these issues by developing innovative, circular, and cost-effective solutions for next-generation 15 MW floating wind turbines. Aligned with the European Green Deal and Horizon Europe priorities, the project strengthens the EU industrial base, reduces reliance on critical raw materials, and supports local job creation.

The project focuses on these key areas:

Blade design: Lightweight, modular blades using recyclable composites and toughening materials to reduce mass and improve performance.
Substructure and anchoring: Circular concrete mixes and aluminium rebar for durable, low-impact floaters and anchors.
Drivetrain: Compact, modular systems with reduced rare earth use and enhanced reliability through predictive maintenance.
System integration: Advanced simulation tools (SIMA, OpenFAST, WRF-LES) to optimize turbine and farm performance, including LCoE and environmental impacts.
Circularity and sustainability: Blade recycling technologies with over 60% material reuse and integrated sustainability assessments.


Pathway to Impact
MADE4WIND delivers measurable benefits across key domains:
Environmental: Lower CO2 emissions via sustainable materials and corrosion-free designs.
Economic: Reduced LCoE and OPEX, improved turbine design with reduced materials, reduced material consumption, and scalable deployment.
Industrial: Strengthened EU manufacturing and reduced raw material dependency.
Social: Job creation towards wind energy sector

Role of Social Sciences and Humanities: While technically focused, the project integrates social sciences in its exploitation strategy, stakeholder engagement, and training design. WP7 ensures alignment with market needs and policy frameworks, while promoting gender inclusivity and open science principles for equitable innovation.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Technical and Scientific Activities and Achievements
MADE4WIND has advanced the development of innovative components for a 15 MW floating wind turbine, focusing on performance, circularity, and sustainability.

1. Blade Design and Manufacturing
Lab-scale preform manufacturing was successfully implemented, and a virtual process chain was initiated to simulate wrinkle defects. Toughening interleaves improved fracture toughness by 274% and reduced fatigue crack growth by 92%. A chemical recycling process recovered glass fiber fabrics with properties comparable to virgin materials, confirmed through mechanical and chemical characterization.

2. Floating Substructure and Anchoring
Ten lightweight concrete (LWC) mixes and two heavyweight concrete (HWC) mixes were developed using recycled aggregates and low-clinker cement. The best LWC achieved 51 MPa strength and 1958 kg/m³ density; HWC reached 3437 kg/m³ and 57 MPa. Acid concrete formulations compatible with aluminium rebars were validated, and thermomechanical models simulated curing effects and stress concentrations.

3. Drivetrain Development
A multi-objective optimization framework was created to minimize drivetrain mass and maximize efficiency. INDAR optimized generator topologies and cooling strategies, while ING designed a modular converter (Basic Power Module) using advanced semiconductors. Reliability was addressed through stray current modeling and lab validation. NTNU built a SIMPACK model to simulate drivetrain dynamics under floating-specific loads.

4. System Integration and Wind Farm Modeling
The IEA 15 MW turbine was selected as the reference. Aero-hydro-elastic models (OpenFAST, SIMA) and WRF-LES simulations were developed for site-specific inflow conditions. A Python-based LCoE tool was created, and predictive maintenance strategies using sensor data and anomaly detection were initiated.

5. Sustainability Framework
Task 6.1 defined the methodology for integrated sustainability assessment. A workshop aligned system boundaries and partner roles for data input, preparing the foundation for future environmental and socio-economic evaluations.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

MADE4WIND has delivered several innovations that advance the current state of floating offshore wind technology, materials, and system integration.

1. Blade Toughening and Recycling
Lightweight blade composites with toughening interleaves achieved up to 274% higher fracture toughness and 92% lower fatigue crack growth, enabling longer, lighter blades. A chemical recycling process recovered glass fiber fabrics with properties comparable to virgin materials.
Next steps: TRL 5 validation and IPR protection.

2. Circular Concrete for Substructures
New lightweight and heavyweight concrete mixes using recycled aggregates and low-clinker cement achieved high strength and reduced CO2 footprint.
Next steps: Manufacturing of component to be tested and validated at TRL 5

3. Aluminium-Reinforced Concrete
Acid concrete formulations compatible with Al6086 alloy rebars reduce corrosion and allow thinner concrete shells, potentially reducing floater mass by 20%.
Next steps: Component casting and validation

4. Modular Drivetrain Architecture
A multi-objective optimization framework integrates gearbox, generator, and converter design, reducing rare earth use and improving reliability.
Next steps: The design steps will be updated every year based on the new input variables.

5. Integrated Simulation and Cost Tools
High-fidelity models (SIMA, OpenFAST, WRF-LES) and a Python-based LCoE calculator enable accurate performance prediction and layout optimization.
Next steps: Licensing and adoption by wind farm developers.

Key Enablers for Uptake
Further R&D: Full-scale testing of blades, drivetrain, and concrete.
Market Access: Support for pilot projects and industrial partnerships.
IPR & Commercialisation: Licensing and patenting strategies.
Standardisation: Engagement with regulators to update design codes.
Internationalisation: Collaboration with global offshore wind initiatives.