GE Renewable Energy Inaugurates 3D Print Wind Turbines Research Facility

GE Renewable Energy launched a new research facility on April 21, 2022. A first of its kind in the United States, the team behind the project hopes it will help lower costs for the renewable energy industry. Specifically, the research will enable GE to 3D print wind turbines on-site at wind farms, reducing transportation costs. It will also create additional job opportunities at the wind farms that use the technology. 

“Innovation will continue to be a major resource in accelerating the energy transition. It’s important to continuously improve how we design, manufacture, transport, and construct the huge components of modern wind farms. We appreciate the support of the US government for this particular research here in Bergen.” – Danielle Merfield, CTO, GE Renewable Energy.

The facility in Bergen, New York, is considered “at the heart” of a collaboration with cement manufacturer Holcim and Cobod, a firm specializing in 3D printing. The multi-year partnership with said companies started way back in 2020.

3D Printed Wind Turbines

GE said that the printer in Bergen is “the size of a three-story building” and can print tower components as tall as 20 meters. Henrik Lund-Nielsen, founder/ and general manager of Cobod, announced the printer was “the largest in the world” and could “print more than 10 tons of real concrete per hour.”

The US Department of Energy grant has helped support the research at the facility. According to the statement, a 20-strong team is working on optimizing the technology. Likewise, the project team foresees that “first applications in the field” will occur in five years.

“Achieving the Biden administration’s vision of carbon free electricity by 2035 and a net-zero economy by 2050 will require more wind energy capacity. We’re proud to work with GE Renewable Energy on this innovative 3D print wind turbine technology which could be a game-changer in how we utilize this resource.” Alejandro Moreno, US Department of Energy Deputy Assistant Secretary for Renewable Power

Moreno also said that American-made taller towers assembled on-site could cut costs, overcome logistical challenges, and accelerate progress toward the project objectives. 

How Companies Are Involved In The Wind Energy Sector

The research shows how companies are involved in the industry and looking to find new ways of developing turbines.

For instance, companies such as Sweden-based Modvion focus on developing wind turbine towers using laminated wood. In April 2020, the firm said it had installed a 30-meter building on an island near Gothenburg.

The significant dimensions of the printer also reflect a growing interest in technology that will allow companies to develop giant wind turbines.

The last few years have seen several significant players in the sector announce details for large turbines.

Other Companies Making Turbines

For example, GE Renewable Energy’s Haliade-X turbine will have a height of up to 260 meters, 107-meter blades, and a rotor diameter of 220 meters.

In China, MingYang Smart Energy released details of a 264-meter tall design that will use 118-meter blades.

Meanwhile, Danish firm Vestas is working on a 15-megawatt turbine with a 236-meter rotor diameter and 115.5-meter blades, while Siemens Gamesa Renewable Energy is developing a turbine that incorporates 108-meter blades with a rotor diameter of 222 meters.

The research conducted at the Bergen, NY facility will allow GE to serve the growing US wind power market better. The American Clean Power Association (ACPA) says that more than 68,000 wind turbines are generating clean power. Statistics reveal that wind power capacity totals 135 GW, making it the fourth-largest source of electricity in the country. The ACPA recognizes GE Renewable as the best manufacturer of wind turbines in the US for four consecutive years.

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