The project successfully designed, manufactured, validated, and demonstrated innovative offshore turbine blades tailored for wind and tidal energy applications. The significant advancements in material innovation, manufacturing processes, and turbine performance, were achived offering a substantial contribution to renewable energy technologies. Key outcomes include new sustainable and nano-engineered materials: two 3R resin formulations optimized for WTB/TTB manufacturing, NE resin formulations incorporating CNTs and graphene enhanced electrical conductivity, enabling advanced lightning protection systems; functionalized graphene-based resistive inks demonstrated excellent thermal outputs for active de-icing; QRS developed for pressure, strain, flow, moisture, and temperature monitoring, integrated and validated for SHM; scalable CF sizing solutions improved fibre-matrix interfacial strength; Functionally Graded (FGAJ) and Multiple Adhesive Joints (MAJ) enhanced joint strength and recyclability, with debonding-on-demand capabilities. Multi-functional coating solutions, including riblet, erosion protection, and antifouling coatings, were developed for W/TTB, enhancing durability, hydrophobicity, and drag reduction.Twenty digital models were created to support de-icing systems, material property predictions, infusion processes, bladelet design, optimization of bi-adhesive and scarf-bonded solutions, validating their accuracy for turbine applications. Intermediate validation confirmed the suitability of 3R composites and joint solutions for demanding conditions, with successful NDT techniques, omniphobic coatings, active de-icing systems, lightning protection, biofouling resistance and underwater cleanability demonstrated for WTB and TTB components. Repairability of 3R composites achieved over 90% recovery in mechanical properties. Two modular 1:20 scale WTB (5.8 m length) and TTB (MADRAS, one-shot) demo validated advanced manufacturing methods, structural integrity and performance, while process monitoring proved reduced waste and improved production efficiency. SHM systems with embedded sensors detected damage modes and provided real-time monitoring for turbine blades, validated through laboratory and field tests. AI-driven models predicted damage evolution and enhanced maintenance strategies. Circular economy principles were successfully integrated into turbine blade design with 3R materials, modular segmentation, and advanced recycling methods. Comprehensive LCA and LCC studies highlighted reduced environmental impact and cost-effectiveness. Risk and safety assessments ensured safe handling of materials and processes. Project results outreached >10 workshops,>17 scientific articles, >32 conferences, 6 exhibitions, 10 workshops. 27 Key Exploitable Results were delivered, supported by business models, commercialization strategies, and synergies with related projects. The Carbo4Power project advanced renewable energy technology, achieving critical innovations in materials, design, and manufacturing while emphasizing sustainability, recyclability, and economic viability.
