Composites for wind turbines | Exel Composites

Composites for stronger and lighter wind turbines

Wind turbine designs continually improve the turbine’s power output capacity and performance.

Blade design is critical, and as turbine manufacturers look to design and manufacture longer, stronger, and lighter blades, composite technologies play a critical role.

With over 20 years experience in the wind industry, global manufacturing, and over 50 years with composites, we work side-by-side with turbine manufacturers to pioneer composite solutions.

Our carbon fiber, fiberglass, and hybrid composite and resin solutions combined with expertise in pultrusion manufacturing provide turbine manufacturers with efficient and economical design solutions.


Blade reinforcement composites

There are two primary reinforcement composite materials used today: fiberglass and carbon fiber. Fiberglass is a high-performance economical composite suitable for many turbine blade designs. As blade designs become longer, and blade weight more critical, carbon fiber reinforcements are typically used. Lighter blades help reduce the overall nacelle weight and therefore the rotor structural support needed.

We have expertise in both consulting with blade designers to determine the best composite based on turbine specification, as well as in the manufacturing of the fiberglass and carbon fiber reinforcements.

We are happy to consult with you on the best composite solution to fit for your design.

Our composite solutions for wind turbines include:

  • Blade reinforcements and rotor blade laminates
  • Spar caps
  • Turbine blade root joints, fiberglass spacers and carrots
  • Cable management systems
  • Service platform structures and ladders
  • Generator insulation solutions

Why pultrusion is important for the wind energy

A combination of design and manufacturing expertise provide our foundation for pultrusion manufacturing.

We understand how to use carbon fiber in the most cost efficient manner to meet cost, weight, and strength requirements, and our pultrusion manufacturing expertise is a key to efficient carbon fiber use.

Pultrusion is a continual process that reduces production waste and time and maintains a consistent production quality compared to other composite manufacturing processes.

With the pultrusion process, composite fibers are first impregnated with a thermoset resin and then are pulled through a heated die where the resin cures. Additional laminate overlays are possible, as well as the addition of reinforcement mats, fabrics and multiaxial products.

Pultrusion benefits include:

  • Precise fiber alignment
  • High quality, wrinkle-free surfaces
  • Faster production and reduced mold times
  • Consistent product quality
  • High strength, high fatigue strength, lower weight compared to traditional materials
  • Would you like a quote or more information on these products? We are happy to help!

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Exel Composites Oyj, Vantaa head office, Mäkituvantie 5, FI-01510 Vantaa, Finland