Wind Energy

Materials, Manufacturing, and Maintenance for Efficient Wind Turbines

Wind energy – both onshore and offshore – is a cornerstone of a resilient European and national electricity supply. To reliably meet the growing demand for cost-effective, renewable energy, wind turbines must be high-performance, durable, easy to maintain, and resource-efficient. Fraunhofer IFAM supports manufacturers, operators, and suppliers throughout the entire value chain with expertise in materials development, manufacturing technology, adhesive technology, quality assurance, and inspection and maintenance systems.

Why Wind Energy Relies on Robust Technologies

Wind turbines are exposed to high mechanical, climatic, and corrosive stresses over decades – especially in offshore applications. At the same time, European manufacturers and operators face intense international competition and must reduce the Levelized Cost of Energy (LCOE), increase availability, and manage risks. High-quality materials, optimized manufacturing processes, and intelligent maintenance concepts are therefore key to competitiveness.

Materials and Manufacturing Expertise for Rotor Blades and Components

Fiber-reinforced composites: Development of bio-based and recyclable resin systems, damage analysis, and training of skilled workers at the Fiber-Reinforced Composites Training Center.
Leading Edge Protection: Anti-erosion coatings to protect the leading edge of rotor blades against rain, sand, and particle impact, thereby extending service life and minimizing yield losses.
Riblet coatings: Microstructured paint surfaces to reduce aerodynamic drag and noise emissions, inspired by shark skin, with automatable application processes.
Adhesive Bonding Technology: High-performance adhesive bonds for the manufacture and repair of rotor blades, including optimized adhesive systems and automated application for higher quality and service life.
Rotor Blade Recycling: Processes such as microwave pyrolysis for the recovery of fibers and recyclable materials from GRP and CFRP rotor blades as a contribution to the circular economy.

Manufacturing, Installation, and Corrosion Protection

Release-agent-free rotor blade manufacturing: Using PeelPLAS^© technology, Fraunhofer IFAM enables release-agent-free production, clean demolding, reduced grinding dust exposure, and improved paintability – for efficient, sustainable processes.
Generators: Mathematical models, high-precision 360° measurement methods in the submillimeter range, and high-performance coatings improve efficiency and reliability. Digital test environments combine electrical, thermal, and mechanical stresses to provide robust service life predictions.
Corrosion protection: Innovative protective coatings and a testing laboratory accredited to DIN EN ISO 17025 ensure the durability of metallic components, particularly for offshore installations, including damage analysis and consulting.

Operation, Inspection, and Repair of Wind Turbines

Offshore Drone Campus Cuxhaven (ODCC): Infrastructure for the development and testing of drone systems for inspection, maintenance, and material logistics under real offshore conditions, including fuel cell propulsion, sensor technology, and regulatory concepts.
Condition-based maintenance: Data-driven analyses and automated inspections, such as those using drones, enable needs-based maintenance strategies, reduce downtime, and lower operating costs (OPEX).
Rotor blade repair: Adhesive repair methods and thermally activatable polymer patches for fast, safe, and material-friendly repairs, with a focus on automatability, emission reduction, and cost efficiency.

Services and Collaboration with Fraunhofer IFAM

We support companies throughout the entire process – from material selection and process development to quality assurance and operational optimization. Our range of services includes: Together, we develop solutions that measurably improve the technical performance, cost-effectiveness, and sustainability of wind turbines.

Feasibility studies
Development projects
Testing services
Scaling support, as well as
Training and education

Feel free to contact us!

Here you will find a selection of our technologies and projects in the field of wind energy:

Joint project MARiLEP

Significant extension of service life in the area of front edge coatings for wind turbines.

To the MARiLEP project

Joint project: AIDA

Autonomous inspection and maintenance of offshore wind turbines through the development of a holistic UAS approach

More about the AIDA joint project

Offshore Drone Campus Cuxhaven

Here, Fraunhofer IFAM develops components, systems, and processes for the use of drones in the offshore sector.

More about the ODCC

Innovative maintenance for wind farms

Fraunhofer IFAM conducts research into innovative maintenance and repair concepts for the offshore sector.

More about innovative wind farm maintenance

Functional coatings with anti-icing effect

Development and testing of application-specific anti-icing technologies.

More about anti-icing coatings

Corrosion protection

Corrosion protection – for safety, functionality, and value retention of materials and components

More about corrosion protection at Fraunhofer IFAM

Potting for the protection of electronic components

Potting ensures that components remain functional in harsh environments.

More about polymer potting

Drone-based lightning protection inspection of wind turbines

Lightning protection inspection using drones

Learn more about drone-based lightning protection inspection of wind turbines (in German)

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How can Fraunhofer IFAM help extend the service life of rotor blades?

Through anti-erosion coatings, optimized bonding techniques, damage analysis, and improved manufacturing processes, we extend the service life of rotor blades and reduce maintenance requirements.
What role do drones play in the maintenance of wind turbines?

Drones enable automated, safe, and cost-effective inspections, particularly in offshore environments, and form the basis for condition-based maintenance strategies.
How does Fraunhofer IFAM contribute to the sustainability of wind energy?

We develop recyclable resin systems, methods for recycling rotor blades, and process-optimized manufacturing solutions that conserve resources and reduce emissions.