Project NEOFOIL

The manufacturing of large fiber-reinforced plastic (FRP) structures for wind turbine rotor blades is a complex process. Until now, release agents have been used that not only require labor-intensive reworking, but also have critical health and environmental impacts. Residues of these release agents on the surfaces prevent direct paintability of the components, making a time-consuming post-orocessing e.g. a sanding process necessary. This process generates considerable amounts of critical grinding dust. In addition, accessibility is limited due to the dimensions of modern rotor blades, both onshore and offshore.

Fraunhofer IFAM has developed an alternative solution: a transfer-free release film that does not require any release agents and thus enables clean surfaces that can be painted directly. Building on this, the research project NEOFOIL has been launched.

 

Project goals

The project is developing a plasma-coated composite film that is fixed to the molding tool as a semi-permanent release film. For the first time, it enables multiple demolding of FRP components, which can significantly increase efficiency in rotor blade production.

At the same time, research is being conducted into an innovative coating system that can be applied directly without prior sanding of the component surface. Two approaches are being pursued to improve the adhesion properties of the coating system:

• Formulation of co-binder components with functional and polar groups to improve the adhesion of the top coat
• Development of a novel in-mold gel coating that is applied and cured directly in the mold to build up the rotor blade on a monolayer coating system

The developed processes will first be tested on a pilot plant tool and then validated in an industrial environment. The aim is to make the production of rotor blades more sustainable, efficient, and economical – thereby strengthening the competitiveness of the German supplier industry in the wind energy sector.

 

The role of Fraunhofer IFAM in the project

Fraunhofer IFAM is leading and organizing the joint project and making significant contributions to its development, testing, and validation:

• Development of the semi-permanent composite film with a focus on plasma polymer coating
• Support in the development of coating materials and adaptation of component surfaces with test benches
• Work on fixing and sealing solutions, development of a laboratory tool and adaptation of a pilot tool, implementation of sensor testing
• Research on the pilot plant tool, testing of the developed components in multiple component productions, validation of the technologies in industrial tool form
• Evaluation and documentation of the work packages and development of exploitation possibilities

The institute is thus making a significant contribution to the successful implementation of NEOFOIL.

 

About the Project

Project partner:

• Mankiewicz Gebr. & Co. (GmbH & Co. KG) | Hamburg,
• TPI Composites Germany GmbH | Berlin,
• VABATEC GmbH | München,
• SYSCribe GmbH | Hamburg
• Olin Germany Upstream GmbH & Co. KG | Stade

 

Funding:

Federal Ministry for Economic Affairs and Energy

 

Funding code:

03EE3112A

 

Duration:

01.09.2024 to 31.08.2027