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A Major Leap in Tidal Energy Manufacturing Thermwood Corporation, Purdue University, the University of Sheffield, the University of Oxford and the University of Edinburgh are working together on an advanced double-sided Large-Scale Additive Manufacturing (LSAM) tool to fabricate a 2-meter tidal turbine blade. This project began at the 2025 JEC Composites Show in Paris and is now ongoing, demonstrating how additive manufacturing is transforming renewable energy production. At JEC 2025, Thermwood’s LSAM 510 printed both sides of this innovative tool live on-site using carbon fiber reinforced polycarbonate (PC), reducing tooling fabrication time from months to weeks. A true leap in efficiency and performance. Advanced Simulation and Precision Machining Purdue University’s ADDITIVE3D technology simulated and optimized the printing process, modeling temperature evolution and post-processing effects. This predictive tool ensures confidence and precision in large-scale additive manufacturing. Following printing, the University of Sheffield’s Advanced Manufacturing Research Centre performed precision machining to integrate sensor placements, blade root locator mounts, and resin inlet and outlet features. Innovative Blade Design and Real-Time Monitoring The blade design features a hybrid configuration for optimal hydrodynamic efficiency and mechanical performance. Embedded sensors, including fiber optic sensing, strain gauges, thermocouples, and accelerometers, allow real-time structural monitoring for manufacturing quality and operational performance. Next Steps: Testing and Impact The blade will undergo fatigue testing at the University of Edinburgh’s FastBlade facility and extended sea trials with a scaled turbine system. These trials will deliver valuable insights for the next generation of high-efficiency tidal turbine blades. More Info here: https://www.thermwood.com/thermwood-t...