BREAKING THE BOTTLENECK Industrialising the Manufacture of Large Wind Blades

Scaling wind turbine blade production is now one of the most significant engineering challenges facing the sector. As blade lengths exceed 100 metres, established manufacturing processes are being pushed beyond their original design intent, creating sustained pressure on productivity, quality, and deployment speed.

This whitepaper provides a clear, engineering-led analysis of the practical factors influencing large-blade manufacture, alongside the measured process advancements supporting the industry’s progression towards wider industrialisation.

What you’ll learn

• The technical and operational factors shaping large-blade manufacturing at scale.
• Why process variability increases with blade size, and practical methods for managing it.
• Advances in resin infusion, process automation, and materials handling.
• Where blade factories can refine process efficiency and reduce mould occupation time.
• The role of data-led process control in achieving repeatability.
• Practical steps towards factory blueprinting and more consistent global manufacturing approaches.
  
  

Who should read this?

Engineering leaders, process specialists, and decision-makers responsible for blade production performance, manufacturing development, and future factory strategy.

Why it matters

As demand accelerates and next-generation turbines dominate order books, manufacturers must continue refining their processes to support reliable, scalable blade production. This paper highlights the engineering considerations and practical approaches that can help organisations progress with confidence, without compromising quality or throughput.

👉 Download the whitepaper to explore how large-blade manufacturing can be industrialised with greater control, consistency, and efficiency.