Additive Manufacturing and Composite Materials for Marine Energy: Case of Tidal Turbine

The global trend in additive manufacturing is the technology of three-dimensional (3D) printing with a high potential to avoid some of the weaknesses of conventional fabrication techniques. This new technology has been used to manufacture small tidal and wind turbines. In isolated areas, small turbines can be manufactured and assembled on-site for green energy production. The purpose of this document is to evaluate the thermomechanical behavior of a printed tidal turbine using Digimat-AM (Additive Manufacturing) with fused filament fabrication method. The finite element computes the mechanical deflection, temperature, residual stresses, and warpage fields of the printed part. The composites used during printing are thermoplastic polymers (acrylonitrile butadiene styrene, polyamide 6 [PA6], polyamide 12 [PA12], and polyetherimide [PEI]) reinforced with carbon and glass fillers in the form of fibers and beads (CF/GF and CB/GB). Through the simulation, one could show that the blade printed with PEI-CB/CF has excellent mechanical performance of low mechanical deflection and warpage, compared to PA6-CB/CF. In addition, the fiber-shaped fillers are better than the bead-shaped ones for the 3D printing process. In general, this study has shown the potential and feasibility of 3D printing as an excellent opportunity in the fabrication of small blades in the future, but more studies are required to understand this potential.