3D Printing of a Tidal Turbine Blade Using Two Methods of SLS and FFF of a Reinforced PA12 Composite: A Comparative Study

Abstract

This study scrutinizes the thermomechanical dynamics of 3D-printed hydrofoil blades utilizing a carbon and glass bead-reinforced thermoplastic polymer. Comparative analyses underscore the pivotal role of polymer reinforcement in augmenting mechanical strength and mitigating deformation and residual stress. The investigation elucidates the expeditious and cost-efficient manufacturing potential of low-cost Fused Filament Fabrication (FFF) printers for small-scale blades, revealing exemplary mechanical performance with nominal deflection and warping in the PA12-CB/GB printed blade. A comprehensive juxtaposition between Selective Laser Sintering (SLS) and FFF printing methods favors SLS due to its isotropic properties, notwithstanding remediable warping. Emphasizing the rigorous marine environment, the study cautions against the anisotropic properties of FFF-printed blades, despite their low mechanical warping. These discernments contribute to hydrofoil design optimization through numerical analysis, shedding light on additive manufacturing’s potential for small blades in renewable energy, while underscoring the imperative for further research to advance these techniques.