Advancing tidal turbine blade manufacturing: exploring current and alternative manufacturing methods

Rotor blades are critical components of tidal energy converters, typically manufactured from thermoset fibre-reinforced composite (FRC) materials using vacuum infusion processing. High load demands result in thick-section laminates (10–100 mm), particularly at the blade root, posing manufacturing challenges. While tidal and wind turbine blades appear similar in design, the fundamentally different operational conditions result in distinct structural differences and, therefore, manufacturing requirements, offering opportunities for the tidal sector to innovate. Advances in materials and manufacturing technologies provide potential to rethink current practices for improved design and process efficiency. Additionally, the relative immaturity of tidal technology allows for early integration of circularity principles, minimising waste and optimising resources. This paper serves as a comprehensive resource for the tidal turbine blade sector, reviewing current manufacturing practices and exploring alternative techniques. Combining knowledge from academic literature and industrial reports, it outlines blade design, material selection, and current manufacturing processes. The paper evaluates emerging techniques and potential modifications to established methods. Due to the range of turbine designs in the sector, optimal materials and manufacturing combinations will differ. This study offers manufacturers valuable insights to support informed and strategic choices to improve and advance tidal turbine blade production.