Wind Energy

Wind energy – both onshore and offshore – is a cornerstone of a resilient European and national energy supply. Its expansion is crucial to sustainably meet the continuing rise in electricity demand, reduce dependence on international supply chains, and further decarbonize our energy supply. In order to secure the growing demand for cost-effective wind energy in the long term, wind turbines must not only become more powerful, but also more durable, easier to maintain, and more sustainable. National and European manufacturers and operators must compete internationally and score points with cost-effective and high-performance products. Fraunhofer IFAM supports companies along the wind energy value chain with comprehensive expertise in materials development, manufacturing technology, adhesive bonding technology, quality assurance, and inspection and maintenance systems.

 

Data and Models for the Development of Wind Turbines

Based on its core competencies in manufacturing technology and materials science, Fraunhofer IFAM supports the wind industry with data and models for the design of plant components. Due to the high proportion of material costs, our expertise in materials and manufacturing technology is particularly in demand in order to improve costs, service life, and efficiency.

Rotor Blades – Fiber Composites:

Modern rotor blades are made of high-strength fiber composites with excellent weight-specific properties. We develop bio-based and recyclable resin systems that not only offer high mechanical properties but are also sustainable. In addition, we perform damage analyses and train specialists in our training center for fiber composites.

Rotor Blades – Leading Edge Protection:

Fraunhofer IFAM develops high-performance coating systems to protect the leading edges of wind turbine rotor blades. These anti-erosion coatings are based on resistant materials that can withstand extreme environmental influences such as rain, sand, and particle impact. The aim is to extend the service life of the rotor blades, minimize yield losses, and significantly reduce maintenance costs.

Rotor Blades – Riblet Coatings:

Our institute develops microstructured paint surfaces with riblet technology to reduce flow resistance and noise emissions on rotor blades. Inspired by the skin structure of fast sharks, these fine grooves minimize turbulent air vortices, improve aerodynamic efficiency, and reduce noise levels at the same time. The automatically applicable coatings increase performance and reduce operating costs.

Rotor Blades – Adhesive Bonding Technology:

Fraunhofer IFAM researches and develops high-performance adhesive bonding technologies for the manufacture and repair of rotor blades. The focus is on structurally resilient adhesive bonds that enable a permanent and secure connection of fiber composite components. Optimized adhesive systems and automated application processes improve quality, make manufacturing more efficient, and increase the service life of components.

Rotor Blades – Recycling:

Fraunhofer IFAM develops sustainable processes for recovering materials from rotor blades. Among other things, the focus is on microwave pyrolysis, which is used to efficiently separate glass and carbon fiber-reinforced plastics from the matrix. The fibers and pyrolysis products obtained can be reused industrially. This increases resource efficiency and makes an important contribution to the circular economy.

 

Manufacturing and Installation

Fraunhofer IFAM also makes decisive contributions to manufacturing and assembly:

Release Agent-free Rotor Blade Manufacturing:

With PeelPLAS^© technology, we have developed a release agent-free solution for rotor blade manufacturing. The deep-drawable release film enables clean demolding, reduces grinding dust pollution, and improves paintability—an important step toward high manufacturing efficiency, manufacturing quality, and sustainability.

Generators:

The efficiency of large generators depends on maximum precision—especially compliance with minimum tolerances. We are working on mathematical models, 360° measurement methods in the submillimeter range, and high-performance coatings to significantly improve efficiency and reliability. In addition, we offer a digital test environment that combines electrical, thermal, and mechanical loads and enables reliable life cycle predictions.

Corrosion Protection:

Corrosion is one of the biggest challenges, especially for offshore installations. We offer innovative protective coatings for metallic components of wind turbines and operate a testing laboratory accredited according to DIN EN ISO 17025. With our combination of material development, damage analysis, and consulting, we ensure the long-term value retention of installations.

 

Operation and Maintenance of the Turbines

The economic profitability of wind turbines depends largely on reliable operation and efficient maintenance.

Offshore Drone Campus Cuxhaven (ODCC):

With the ODCC, we have created a unique testing and development infrastructure for unmanned aerial systems (UAS). Here, we enable the testing and further development of drone systems for inspection, maintenance, and material transport under real offshore conditions. Research focuses on weather-resistant drone systems, the integration of fuel cell drives, the optimization of sensory end effectors, and the design of regulatory processes for regular operation.

Condition-based Maintenance:

Traditional, rigid maintenance intervals result in high operating costs. By using automated inspection methods—such as drones with precise sensor technology—and data-based analyses, we develop strategies for maintenance measures tailored to specific needs. This reduces downtime and lowers operating costs (OPEX).

Rotor Blade Repair:

Fraunhofer IFAM develops innovative repair methods for fiber-reinforced plastics that can be used in rotor blades. The focus is on adhesive solutions and thermally activatable polymer patches that enable fast, safe, and material-friendly repairs. Automated processes and new material systems make repairs more efficient, lower in emissions, and more cost-effective.

 

Services and Cooperation

We support manufacturers, operators, and suppliers with practical research and technological consulting—from material selection to process development and quality assurance to operational optimization. Our services include feasibility studies, development projects, testing services, scaling support, and training courses.

Please feel free to contact us.