Forging the blades of the future with composite materials with circular, safe and sustainable design

Project Information

BLADE2CIRC

Grant agreement ID: 101147451

DOI

10.3030/101147451

EC signature date 21 March 2024

Start date 1 April 2024

End date 30 September 2027

Funded under

• Climate, Energy and Mobility

Total cost

€ 3 969 228,75

EU contribution

€ 3 969 228,75

Coordinated by

FUNDACION AITIIP
Spain

Periodic Reporting for period 1 - BLADE2CIRC (Forging the blades of the future with composite materials with circular, safe and sustainable design)

Reporting period: 2024-04-01 to 2025-05-31

Summary of the context and overall objectives of the project

The BLADE2CIRC project emerges in response to the urgent need for sustainable solutions in the wind energy sector, particularly addressing the environmental and economic challenges posed by the end-of-life management of wind turbine blades. These blades, typically made from complex composite materials, are difficult to recycle and often end up in landfills or incineration, contributing to environmental degradation and resource inefficiency.

BLADE2CIRC aims to transform this linear model into a circular one by developing and validating innovative, bio-based composite materials and circular design strategies. The project focuses on enabling the reuse, recycling, and repurposing of wind turbine blades, thereby reducing waste and extending the lifecycle of materials. This aligns with the European Green Deal and the EU Circular Economy Action Plan, which prioritize sustainable resource use and decarbonization of energy-intensive industries.

The project brings together a multidisciplinary consortium of industrial and academic partners to co-develop new materials, manufacturing processes, and business models that support circularity. It also integrates life cycle assessment (LCA) and techno-economic analysis (TEA) to ensure that the proposed solutions are not only environmentally sound but also economically viable.

BLADE2CIRC is expected to deliver significant impacts at multiple levels (pathway to impact):

Environmental Impact - Circular use of composite materials
Industrial Impact - Scalable solutions for the wind energy sector and composite manufacturing industries
Policy and Strategic Alignment - The project supports EU strategies on climate neutrality, resource efficiency, and industrial resilience
Societal Impact - The project will raise awareness and build capacity for circular practices in renewable energy infrastructure.

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

During the first reporting period (M1–M14), the BLADE2CIRC project has made substantial progress toward its goal of enabling circularity in wind turbine blade (WTB) design through the development of sustainable, high-performance composite materials and circular design strategies.

1. Material Innovation and Development
The project successfully synthesized and characterized several bio-based thermoset resins, including a 100% biobased and bisphenol-free DGEVA resin, which received BBC certification.
Novel dynamic covalent chemistries were explored to enable recyclability and self-healing properties in composite matrices.
The first results for UPP (unspecified polymer precursor) synthesis and purification were achieved, and reactive diluents (RDs) were targeted, supplied, and synthesized to tailor the resin formulations.

2. Composite Processing and Manufacturing
The project validated the processability of conventional composite manufacturing techniques such as resin transfer molding (RTM) and vacuum infusion to be used as benchmark.
Pilot-scale trials demonstrated the feasibility of integrating the new materials into blade-relevant geometries, ensuring compatibility with industrial-scale production.

3. Modelling and Simulation
Advanced material modelling was conducted to predict the mechanical performance and degradation behavior of the new composites under operational and end-of-life conditions.
Simulation tools were refined to support design-for-recyclability approaches, enabling the optimization of blade structures for circularity from the outset.

4. Circular Design and End-of-Life Strategies
The project developed design guidelines that integrate circularity principles, including modularity, ease of disassembly, and material separation.
One workshop was organised with partners to start unveiling the end-of-life scenarios.

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)

At this stage of the BLADE2CIRC project, several technical and scientific milestones have been reached, laying a strong foundation for future impact. The project is progressing toward its goal of enabling circularity in wind turbine blade (WTB) design and end-of-life management through bio-based materials and recyclable composite systems.

Results so far include:
Bio-based Resin Systems: Multiple resin formulations have been developed and validated, including a 100% biobased, bisphenol-free DGEVA resin. These materials are tailored for recyclability and mechanical performance.
Dynamic Covalent Chemistry: Reversible crosslinking systems have been introduced to enable repair, reshaping, and recycling of thermoset composites.
Recycling Pathways: Mechanical and chemical recycling routes have been tested with promising results. Early-stage LCA and TEA indicate potential for environmental and economic viability.
Design-for-Circularity: Guidelines for modular and disassemblable blade designs have been drafted and are being integrated into demonstrator components.
Demonstrators: Initial theoretical guidelines were established for the prototype that will be manufactured at the end of the project to validate the performance of new materials and designs under realistic conditions.


While full-scale impacts will be assessed in later phases, the project is already showing potential in several areas:

Environmental: Reduction in composite waste and CO2 emissions through recyclable, bio-based materials.
Industrial: Increased readiness of sustainable materials and processes for integration into existing manufacturing lines.
Scientific: Contributions to the state of the art in dynamic thermoset chemistry and circular composite design.
Policy Alignment: Strong alignment with EU Green Deal, Circular Economy Action Plan, and Horizon Europe Cluster 5 priorities.


To ensure the long-term success and uptake of BLADE2CIRC innovations, the following enablers have been identified: further research, full-scale demonstration, market access and finance, commercialisation and IPR, standardisaition and regulation and internationalisation.