Cost analysis and manufacturing process of blade prototypes with different structural configurations for a 1 kW H-type vertical axis wind turbine.

Abstract

This article analyzes the costs associated with the manufacturing processes of prototype blades, each measuring 2 meters in length and featuring a NACA 0015 aerodynamic profile, with different structural configurations for a 1 kW H-type vertical axis wind turbine (VAWT). The research identifies the material costs and mass of the blades in order to optimize their manufacturing and achieve efficient performance. The objective is to improve resource efficiency in both research and industrial processes. Two manufacturing methods are evaluated: hand lay-up molding (Prototype A) and vacuum-assisted resin transfer molding (VARTM, Prototypes B and C). The evaluation criteria included manufacturing cost, weight, and quality. Prototype A, a single-piece blade with an EPS core, showed the lowest mass (5.11 kg) and cost, though it required significant surface repairs due to resin slippage, which could affect aerodynamic performance. Prototypes B and C, produced by VARTM with a double-shell design, achieved superior surface quality and a controlled fiber-to-resin ratio (100:50). Prototype B weighed 5.81 kg, while Prototype C, reinforced with a polyurethane core for greater rigidity, was the heaviest at 7.22 kg. However, their manufacturing costs were considerably higher: 215% (B) and 312% (C) compared to Prototype A, mainly due to the use of specialized materials. The results highlight the trade-offs between cost, mass, and quality, offering a reference for the development of structurally efficient and economically viable VAWT blades for urban applications. The conclusions are especially relevant for guiding future design and manufacturing decisions for VAWTs intended to operate in challenging environments characterized by turbulent and low-speed winds.