Imagine baking a giant cake where you can't see inside until it's finished, often leading to wasted batches. This project puts 'smart sensors' and a digital mirror of the process inside the mold to catch mistakes as they happen. It's like having an X-ray and a GPS for the factory line to ensure every blade is perfect before it leaves the mold.
Wind turbine blade manufacturing relies on outdated 1970s methods, leading to high defect rates. This results in millions of tons of unrecyclable scrap and costly manual repairs.
A digital twin and data warehouse for real-time production monitoring. An in-line NDT system combining dielectric, wireless, and sensor-less technologies, plus a sub-surface coating inspection tool using ultrasound and mid-IR OCT.
If you are a blade manufacturer dealing with high scrap rates and unrecyclable waste—this project developed a digital twin and in-line NDT that can reduce repairs by 90%. This prevents the creation of millions of tons of scrap.
If you are a producer dealing with hidden defects in large composite shells—this project developed a combination of ultrasound and mid-IR OCT for detailed sub-surface inspection. This allows for precise quality control without destroying the part.
If you are a shipbuilder dealing with resin infusion defects in large hulls—this project developed ML-based closed-loop process control. This optimizes efficiency and minimizes waste during the casting process.
Based on available project data, the specific commercial price for the system is not listed, though the EU provided 6,813,734 EUR for development.
Yes, the project includes a full-scale demo on a wind turbine blade section larger than 80 meters at the SGRE factory in Aalborg.
Based on available project data, the project includes a business plan and exploitation activity to manage the transition from research to market.
It integrates via a digital twin and data warehouse that combines production equipment data with in-line NDT sensors for real-time analysis.
The project runs from October 2022 to September 2026, suggesting the technology will be fully validated by late 2026.
The consortium is heavily industry-driven with a 58% industry ratio, comprising 12 partners across 6 countries. With 7 industrial partners, including 4 SMEs, the project is designed for commercial uptake rather than pure academic research, ensuring the tools developed are practical for factory floors.
Contact Danmarks Tekniske Universitet (DTU) regarding the TURBO project
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