A wind turbine blade includes a lengthwise portion that extends between a root region and a tip region of the wind turbine blade. The lengthwise portion includes a cross section in which a first region surrounds a second region. The densities of the first and second regions vary with the first density being greater than the second density. The lengthwise portion includes a surface layer that bounds the first region, forms an exterior surface, and is configured to resist environmental degradation. At least one structural element extends longitudinally through the first region and is configured to reinforce the blade during use of the wind turbine. The lengthwise portion of a wind turbine blade may be made through an additive manufacturing process by depositing a main body in a plurality of layers. Each layer may be deposited in a plane generally parallel to a longitudinal axis of the lengthwise portion.

A main beam for wind turbine blade, comprising: one or more carbon fiber pultruded bodies, wherein, each carbon fiber pultruded body comprising one or more carbon fiber pultruded sheets, the carbon fiber pultruded sheets are stacked along the thickness direction and are formed by curing a first infusion material, wherein a glass fiber infusion material is arranged between every two carbon fiber pultruded sheets; one or more inlays, which are arranged adjacent to the carbon fiber pultruded body in a direction perpendicular to the thickness direction of the main beam; one or more overlays, which cover the carbon fiber pultruded bodies and/or the inlays on both sides in the thickness direction of the main beam; and a second infusion material, which impregnates carbon fiber pultruded bodies, the inlays and the overlays.

An integral ring gear and torque arm for a wind turbine gearbox and method of manufacturing same includes forming the ring gear and the associated gear housing as a single part using the same material, e.g., using a casting process. Further, the ring gear defines an inner circumferential surface having a plurality of gear teeth. Thus, the method also includes applying a coating material to the gear teeth of the ring gear via an additive manufacturing process, such as cold spraying, so as to increase a hardness of gear teeth.

A component has a first structural configuration and a second structural configuration. The component includes a sensor assembly including a plurality of interconnected structural members defining a plurality of load paths. A first structural member and a second structural member define a first load path when the component is in the first structural configuration. The first structural member and a third structural member define a second load path when the component is in the second structural configuration. The second load path is configured to bypass the second structural member. The sensor assembly is configured to detect a characteristic of the component that changes when the component switches between the first structural configuration and the second structural configuration.

A method of making an elongate wind turbine blade is described. The wind turbine blade extends longitudinally between a root end and a tip end in a spanwise direction, and the method comprises: (a) providing an elongate mould tool (20) extending longitudinally in a spanwise direction; (b) arranging an elongate spar structure (40) in the mould tool, the spar structure (40) N extending longitudinally in the spanwise direction; (c) arranging core material (24) adjacent to the spar structure (40); (d) providing resin-permeable material (114) between the spar structure (40) and the core material (24); and (e) administering resin into the mould during a resin infusion process. The resin-permeable material (114) restricts the flow of resin between the spar structure (40) and the core material (24) in the spanwise direction and thereby substantially prevents lock-offs from forming during the infusion process.

Methods for joining a first blade component and a second blade component of a rotor blade together includes printing and depositing, via a computer numeric control (CNC) device, at least one three-dimensional (3-D) grid structure at a first joint area of the rotor blade. The first joint area contains the first blade component interfacing with the second blade component. The method also includes providing an adhesive at the first joint area to at least partially fill the grid structure. Further, the method includes securing the first blade component and the second blade component together at the first joint area via the adhesive.

A tower for a wind turbine may include an upper tower portion and a lower tower portion. The upper tower portion may include a tubular tower, and the lower tower portion may include a lattice tower. To improve ergonomics and work safety and make it possible to obtain a structural design with optimized forces, the lower tower portion may include a central tube positioned centrally within the lattice tower. Further, the central tube may have a smaller diameter, at least in certain portions, than at least part of the tubular tower of the upper tower portion. The tower may also include a transition piece between the upper tower portion and the lower tower portion. The transition piece may join the tubular tower of the upper tower portion and the central tube of the lower tower portion.

A carrier and at least one pin shaft of a gearbox of a wind turbine and method of manufacturing same includes forming the carrier and the pin shaft(s) as a single part or separate components. Further, the method includes forming one or more voids in the pin shaft(s) and/or the carrier via additive manufacturing. As such, the void(s) is configured to increase flexibility of the pin shaft(s)/carrier so as to improve a load distribution thereof.

A method for manufacturing a rotor blade panel of a wind turbine includes placing a mold of the rotor blade panel relative to a computer numeric control (CNC) device. The method also includes forming one or more fiber-reinforced outer skins in the mold. The method also includes printing and depositing, via the CNC device, printing and depositing, via the CNC device, a plurality of rib members that intersect to form at least one three-dimensional (3-D) reinforcement grid structure onto an inner surface of the one or more fiber-reinforced outer skins before the one or more fiber-reinforced outer skins have cooled from forming. Further, the grid structure bonds to the fiber-reinforced outer skin(s) as the structure is deposited. In addition, the plurality of rib members include, at least, a first rib member extending in a first direction and a second rib member extending in a different, second direction. Moreover, the first rib member has a varying height along a length thereof.

A method for manufacturing an outer skin of a rotor blade includes forming an outer skin layer of the outer skin from a first combination of at least one of one or more resins or fiber materials. The method also includes forming an inner skin layer of the outer skin from a second combination of at least one of one or more resins or fiber materials. More specifically, the first and second combinations are different. Further, the method includes arranging the outer and inner skin layers together in a stacked configuration. In addition, the method includes joining the outer and inner skin layers together to form the outer skin.