Wind energy is helping to decarbonize the electrical grid, but wind blades are not recyclable, and current end-of-life management strategies are not sustainable. To address the material recyclability challenges in sustainable energy infrastructure, we introduce scalable biomass-derivable polyester covalent adaptable networks and corresponding fiber-reinforced composites for recyclable wind blade fabrication. Through experimental and computational studies, including vacuum-assisted resin-transfer molding of a 9-meter wind blade prototype, we demonstrate drop-in technological readiness of this material with existing manufacture techniques, superior properties relative to incumbent materials, and practical end-of-life chemical recyclability. Most notable is the counterintuitive creep suppression, outperforming industry state-of-the-art thermosets despite the dynamic cross-link topology. Overall, this report details the many facets of wind blade manufacture, encompassing chemistry, engineering, safety, mechanical analyses, weathering, and chemical recyclability, enabling a realistic path toward biomass-derivable, recyclable wind blades.

Many marine energy systems designers and developers are beginning to implement composite materials into the load-bearing structures of their devices, but traditional mold-making costs for composite prototyping are disproportionately high and lead times can be long. Furthermore, established molding techniques for marine energy structures generally require many manufacturing steps, such as secondary bonding and tooling. This research explores the possibilities of additively manufactured internal composite molds and how they can be used to reduce costs and lead times through novel design features and processes for marine energy composite structures. In this approach, not only can the composite mold be additively manufactured but it can also serve as part of the final load-bearing structure. We developed a conceptual design and implemented it to produce a reduced-scale additive/composite tidal turbine blade section to fully demonstrate the manufacturing possibilities. The manufacturing was successful and identified several critical features that could expedite the tidal turbine blade manufacturing process, such as single-piece construction, an integrated shear web, and embedded root fasteners. The hands-on manufacturing also helped identify key areas for continued research to allow for efficient, durable, and low-cost additive/composite-manufactured structures for future marine energy systems.

Osteoclasts are multinucleated cells responsible for the resorption of bone and other mineralized tissues during development, physiological remodeling, and pathological bone loss. Osteoclasts have the ability to resorb substrate while concurrently migrating. However, the subcellular processes underlying migration are not well understood. It has been proposed that, in other cell types, cytosolic free Ca²⁺ concentration ([Ca²⁺]_i) regulates cell protrusion as well as retraction. Integration of these distinct events would require precise spatiotemporal patterning of subcellular Ca²⁺. The large size of osteoclasts offers a unique opportunity to monitor patterns of Ca²⁺ during cell migration. We used ratiometric imaging to map [Ca²⁺]_i within rat and mouse osteoclasts. Migration was characterized by lamellipodial outgrowth at the leading edge, along with intermittent retraction of the uropod. Migrating osteoclasts displayed elevation of [Ca²⁺]_i in the uropod, that began prior to retraction. Dissipation of this [Ca²⁺]_i gradient by loading osteoclasts with the Ca²⁺ chelator BAPTA abolished uropod retraction, on both glass and mineralized substrates. In contrast, elevation of [Ca²⁺]_i using ionomycin initiated prompt uropod retraction. To investigate downstream effectors, we treated cells with calpain inhibitor-1, which impaired uropod retraction. In contrast, lamellipodial outgrowth at the leading edge of osteoclasts was unaffected by any of these interventions, indicating that the signals regulating outgrowth are distinct from those triggering retraction. The large size of mature, multinucleated osteoclasts allowed us to discern a novel spatiotemporal pattern of Ca²⁺ involved in cell migration. Whereas localized elevation of Ca²⁺ is necessary for uropod retraction, lamellipod outgrowth is independent of Ca²⁺—a heretofore unrecognized degree of specificity underlying the regulation of osteoclast migration. © 2014 American Society for Bone and Mineral Research.

The National Renewable Energy Laboratory worked with Verdant Power to manufacture, and characterize, novel thermoplastic composite blades on their Gen5d 5 m diameter turbines at the Roosevelt Island Tidal Energy (RITE) site in the East River in N.Y. to demonstrate a low-cost manufacturing process for marine energy structures. Verdant had designed, manufactured, and deployed epoxy thermoset composite blades on three Gen5d turbines in October 2020. At a maintenance cycle in May 2021, a Gen5d turbine equipped with the NREL thermoplastic blades was deployed and retrieved in October 2021. Modal, static and fatigue structural characterization was performed on both blade types before and after the deployment. The static and modal test results showed that the thermoplastic blades were slightly stiffer than the epoxy blades both dry and after the deployment. The epoxy blades had about 8% increase in strain at the applied load after the deployment, whereas the thermoplastic blade strains were not changed significantly. Ultimately the thermoplastic blade failed during fatigue testing due to a crack which is thought to have initiated between the internal foam and the laminate at the location of the internal instrumentation. The Verdant Power Gen5d epoxy blades did not have this internal instrumentation and did not have this failure, performing adequately through the operational period. A lack of design information and fatigue data for both the thermoplastic laminates and the adhesive used means that further work is needed to fully understand his failure and the root cause analysis is ongoing. This paper provides details on the thermoplastic blade manufacturing, materials, test methodology and results.

The National Renewable Energy Laboratory manufactured, instrumented, and deployed thermoplastic composite blades and a data acquisition system (NDAQ) on one of Verdant Power’s Gen5d 5 m diameter tidal turbines in New York’s East River. The thermoplastic blades had internal strain gages, and the NDAQ was a stand-alone system for monitoring and recording the strain and angular position of the blades. The turbine with thermoplastic blades operated and produced power successfully for 3 months, contributing energy to the New York City electric grid. The NDAQ hardware, instrumentation, and structure all survived the deployment and were still functional upon retrieval of the system, but no data were collected. Even though the data retrieval was not a success, data acquisition for deployed subsea marine renewable structures is a new undertaking, and it is critical to share lessons learned from national laboratory experiences. The successful deployment of thermoplastic composite blades marks a significant advancement toward improved materials for subsea components, as well as an advancement in recyclable composite materials. This article outlines the methodology and lessons learned for the instrumentation and data acquisition system.