Finite Element Analysis of Different Infill Patterns for 3D Printed Tidal Turbine Blade

The fabrication route for tidal turbine blades has been compounded with the appearance of additive manufacturing; with the use of infill patterns, improvement of mechanical strength and material reduction for 3D printed parts can be obtained. Through finite element analysis and three-point bend tests, the optimal infill lattice pattern, and the viability of the shell-infill turbine blade model as an alternative to the conventional shell-spar model was determined. Out of a selection of infills, the best infill pattern was determined as the hexagonal infill pattern oriented in-plane. A representative volume element was modeled in ANSYS Material Designer, resulting in the homogenized properties of the in-plane hexagonal lattice. After validation, the homogenized properties were applied to the tidal turbine blade. The shell-infill model was based on the volume of the final shell-spar model which had a blade deflection of 9.720% of the blade length. The difference in the deflection between the homogenized infill and the spar cross-section was 0.00125% with a maximum stress of 170.3 MPa which was within the tensile strength and flexure strength of the carbon fiber with onyx base material. Conclusively, the homogenized infill was determined as a suitable alternative to the spar cross-section. The best orientation of the infill relative to the horizontal orientation of the blade was 0 degrees; however, the lack of trend made it inconclusive whether 0 degrees was the absolute optimal infill orientation.