Fraunhofer develops recyclable rotor blades

29.04.2026

Source: E & M powernews

Together with partners in the EU project "RECREATE", Fraunhofer IWU has presented a rotor blade concept designed to facilitate repairs and improve material cycles in wind power.

With the expansion of wind energy, the question of how to recycle end-of-life turbine components sustainably is also growing. Rotor blades in particular are considered a challenge for the circular economy. Today, they are mostly made of glass fiber-reinforced composite materials and, according to the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in Chemnitz, have a service life of around 20 years. They would have to be replaced after around 30 years at the latest.

As the expansion of wind power in Europe increased significantly shortly after the turn of the millennium, large quantities of old rotor blades will reach the end of their useful life in the coming years. According to the IWU, several tens of thousands of tons of composite materials will then be produced each year. Traditional disposal methods such as thermal recycling or shredding for mixing into cement are not considered sustainable solutions by the researchers. Landfilling is prohibited in the European Union.

Repairing instead of replacing

Against this background, the IWU has developed a new design principle for rotor blades together with partners in the EU project Recreate. The aim is to make wear-prone components replaceable and to use more recyclable materials.

According to the institute, a central weak point of today's rotor blades is the leading edge. This area is permanently exposed to wind, rain and dust and wears out particularly quickly depending on the location. If this edge cannot be replaced separately, the entire rotor blade often has to be replaced.

The research team led by Justus von Freeden from the Fraunhofer IWU in Wolfsburg therefore relies on a modular design. A continuous load-bearing spar forms the basis of the demonstrator. Other components are attached to it. According to IWU, the front edge is made of thermoplastics and natural fibers and is mounted using a detachable adhesive connection. This means it can be replaced when worn.

The institute also points to operational advantages. With increasing abrasion on the leading edge, the aerodynamics deteriorate, which reduces efficiency. Timely replacement can therefore keep the energy yield and efficiency of a system stable over a longer period of time.

Automated production

In addition to repairability, the concept aims to achieve more automated production in Europe. Another focus is on the materials used. The IWU considers natural fiber-reinforced thermoplastics to be more suitable for reuse, repair, refurbishment and recycling. Compared to glass fiber-reinforced plastics, they are said to withstand mechanical recycling processes better. When shredded and remelted, the material gradually loses its properties.

According to the IWU, the Recreate project brought together around 20 partners from research and industry. The project was coordinated by the Politecnico di Milano in Italy. Participants included the Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut (WKI), Braunschweig, Invent GmbH from Braunschweig and other companies and universities from several European countries. The project was funded by the European Union's Horizon Europe research program.

Further information on the Recreate project is available on the Internet.

Author: Susanne Harmsen