Sustainable ultralight construction for wind energy redefined: NECTO® by Matrix-Module with CAIQ design
In the wind energy industry, companies face the challenge of realizing ever-larger rotor blade lengths while solving transportation and disposal problems. An efficient lightweight construction concept is of central importance. Matrix-Module has developed an ultralight construction solution based on metal sheets with NECTO® technology. In collaboration with CAIQ, this technology is optimized through simulation-driven design to meet the high demands for stability, strength, and service life. The partnership with beventum enables the development of innovative metal rotor blades that are not only lighter but also recyclable and potentially divisible, thus making a significant contribution to more sustainable wind energy.
beventum, a subsidiary of the German Federal Agency for Leap Innovations, conducts research in the field of wind energy and is building the world’s first high-altitude wind turbine. For the necessary extremely stable and lightweight structures, beventum relies on the NECTO® ultralight construction technology patented by Matrix-Module. Matrix-Module develops innovative products in collaboration with partners from various industries (wind power, caravan, photovoltaics, solar thermal).
NECTO® meets AI simulation: The future of metal wind turbine blades
Initial situation
- Conventional, non-separable rotor blades made of composite materials lead to transport and disposal challenges
- Limited experience in the design of metal rotor blades regarding stability and fatigue strength, especially in lightweight construction
- Increasing outsourcing of manufacturing to foreign countries
Solution
- Solution for virtual development and design of separable metal rotor blades by CAIQ and Prof. Dr.-Ing. Klemens Rother
- Geometry creation using FCM (CATIA plugin) and structural design with ANSA & LS-Dyna
- Automation of model generation, analysis, and structural evaluation using Python scripts
- Combination of CAIQ’s simulation expertise and NECTO® technology enables the development of lightweight, stable metal sandwich panels
Benefits
- Precise, simulation-based design of innovative metal structures for rotor blades or tower components
- Near real-time design and rapid, data-driven load optimization enabled by AI-based modeling in the future
- Simplified transfer of optimized designs into manufacturing enables more efficient production chains and reshoring of value creation to Germany/Europe
- Development of sustainable, recyclable rotor blades accelerates the energy transition
“beventum GmbH is very satisfied with the cooperation with CAIQ. Through complementary, validated tests, robust models for the design of wind turbine components could be developed – a real added value for our projects.”Markus Grünert, Project Manager at beventum
Advantages of ultralight construction with NECTO® structures and CAIQ design
Sustainability through clean separation during recycling
Leaner production chain
Easier transport due to divisible metal parts
Innovation in ultralight construction: From bird bones to sheet metal structures
NECTO® has developed a bionic model based on the properties of bird bones. It is used to transfer the properties of bones to sheet metal structures, enabling innovative, lighter, and more stable designs.
For questions about the reference project, please contact
Matrix-Module
Dr. Maximilian Scherff
