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Wind Blades’ Lamination Tooling image

The production of lamination tooling for wind turbine blades has traditionally been complex, costly, and resource-intensive. With LFAM technology, Caracol developed an alternative approach based on large-format robotic 3D printing, enabling the production of precise tools tailored to complex blade geometries.

This approach allows manufacturers to accelerate production cycles, improve part quality, and significantly reduce material waste.02-Wind-Blades-Lamination-Tooling

From recycled materials to functional tooling: the RARe-WASTE project

The project was developed within the EIT Manufacturing Demo4Green program through the RARe-WASTE initiative (Robotic Large Format Additive Remanufacturing from Recycled Waste), with the goal of demonstrating how additive manufacturing can support circular economy models.

The case study focused on the production of a wind blade lamination tool using recycled composite materials. The project involved collaboration with industrial and research partners, including MADE Competence Center i4.0 and Enel Green Power. Caracol’s Heron AM platform was used to process recycled materials, including glass fiber reinforced polymers recovered from end-of-life components.

Production data

  • Technology: LFAM Heron AM
  • Material: Recycled PP glass fiber (rPP GF)
  • Application: Wind blade lamination tooling
  • Process: Large-format 3D printing with recycled composites
  • Validation: Functional testing, CT scans, and porosity analysis (max 0.2 mm)

The tooling was validated both technically and functionally, meeting required dimensional tolerances and surface quality standards.03 Wind Blades' Lamination Tooling

Impact on sustainability and manufacturing performance

The project demonstrated how LFAM can deliver measurable benefits in both environmental and production performance:

  • Lead time reduction: Up to 50% faster than traditional processes
  • Raw material savings: Up to 72% reduction
  • Waste reduction: Up to 90% less material waste
  • Use of recycled materials: Recovery and reuse of end-of-life composite components
  • Validated performance: Maintained tolerances and surface quality
  • Circular economy support: Integration of recycling, manufacturing, and end-use

This case highlights the potential of LFAM to enable more sustainable production models, not only in the renewable energy sector but also across industries such as aerospace and automotive.

LFAM as an enabler of sustainable manufacturing

The integration of local supply chains, recycled materials, and additive manufacturing represents a concrete step toward more sustainable industrial processes. Projects like RARe-WASTE demonstrate how LFAM can extend material life cycles while reducing environmental impact.

Caracol continues to develop solutions that combine industrial performance with sustainability, supporting the transition toward more efficient and responsible manufacturing.04-Wind-Blades-Lamination-Tooling

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