ComponentLab
ComponentLab at DTU Wind is a state-of-the-art facility dedicated to advancing wind turbine blade manufacturing, testing, and drivetrain research. It features a versatile 12.6-meter blade mold platform for scalable innovation in composite materials and industrialized production processes, supported by integrated sensing technologies for predictive modeling.
Wind turbine blades are key aerodynamic and structural components of modern megawatt-scale wind turbines. As blade length has increased over time, from just several meters long to modern blades that are well over 100 meters in length, manufacturing these large composite structures has become exponentially challenging. DTU Wind is pushing the boundaries of blade manufacturing with a lab area dedicated to showcasing cutting-edge materials, pioneering new manufacturing techniques, and integrating advanced monitoring and sensing technologies for next-generation wind turbine blades.
Our 12.6-meter blade molds offer a cost-efficient and highly versatile platform for research and demonstration at scale - ideal for collaborative projects and attractive to potential customers seeking innovation without compromising budget.
With this blade material and manufacturing research facility, DTU Wind actively contributes to the industrialization strategy of wind blade production by bridging the gap between research and scalable manufacturing. The setup enables faster validation of new processes and materials, supporting the transition from prototypes to mass production and strengthening Denmark’s position as a leader in wind energy innovation.
Whether for research and development or for wind turbine blade certification, DTU Wind’s ComponentLab is well-positioned to offer industry and research partners a range of full-scale wind turbine blade structural testing options. The laboratory has three test stands with capacities for 15-meter, 25-meter, and 45-meter blades. Structural blade testing programs include blade mass properties, full modal analysis, static testing in multiple directions, lifetime fatigue testing – including flap, edge, or combined loading, and static test to failure, all in accordance with IEC 61400-23: Full-scale structural testing of rotor blades.
Test stands
The three test stands are designed to withstand the highest static loads in the vertical direction. Fatigue loads can be applied in any direction. The floor has built-in rails, which makes it flexible to apply loads where needed.
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45 m test stand |
25 m test stand |
15 m test stand |
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Maximum bending moments on test stands |
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Static |
20.0 |
3.5 |
1.0 |
MNm |
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Dynamic, amplitude |
6.0 |
1.0 |
0.4 |
MNm |
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Maximum deformaitons during test |
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Static tip deflection |
13.5 |
10.0 |
5.0 |
m |
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Dynamic tip-to-tip |
11.0 |
6.0 |
4.0 |
m |
Loading equipment
The facility has a number of static servo-hydraulic actuators, which will be able to provide point loading up to 300 kN and displacements up to 13 m. In fatigue, a number of hydraulic mass resonance excitation actuators provide the possibility to do single or dual axis fatigue at a broad band of resonance frequencies.Measuring equipment
The facility has many possibilities to do advanced measurements and data acquisition. These are among other things
- 3D full field displacements with digital image correlation systems
- Strain gauges (quarter, half and full bridge) and Fiber Bragg Grating sensors
- Displacements with LVDT and ASM
- Scanning laser Doppler vibrometer for vibrations and modal analysis
- High speed cameras, video, thermal imaging camera
- Failure and cracks can be studied with Acoustic Emission, ultrasound scanning and X-ray imaging
Possible projects and activities
At Large Scale Facility, it will be possible to make different projects and activities. There could be:- Blade testing, static and fatigue (single and dual axis)
- Modal analysis
- Demonstration of new sensors and measuring equipment
- Develop special test setups that require much space
- Develop new advanced test methods
- Design, manufacture and test small blades in order to make cost-effective and fast pilot tests of new concepts before scaling up to full size
- Contact us for other test needs
Research and development support
The facility is supported by a dedicated team who does research in the areas of experimental, numerical and analytical design theory. Furthermore, the team develops more reliable and precise methods for structural design of wind turbine blades and other large composite and metal structures.
The team develops methods to predict the structural response of large structures subjected to complex loading. The team does research in understanding failure mechanisms and progressive damage under both static and dynamic loading. Furthermore, the team develops testing methods and measuring equipment for testing at full scale and for testing parts of structures.
Funding
The facility is part of Villum Center for Advanced Structural and Material Testing (CASMaT).The facility is built for DTU Wind Energy by the Danish Building and Property Agency The advanced equipment for tests and measurements is funded by VILLUM FONDEN.
At DTU Wind’s ComponentLab, a cutting-edge Hexapod prototype machine has been acquired to advance research into bearing and drivetrain performance, enabling deeper scientific insight into damage mechanisms and failure modes. This high-tech platform allows for dynamic, multi-axis testing that simulates real-world conditions with high accuracy.
In addition to the Hexapod, large-scale bearing tests are conducted using blade test stands and custom-designed setups, ensuring robust validation across a range of operational scenarios. These capabilities position ComponentLab as a key player in driving reliability and performance in wind turbine components.