TOX-Rotorblades is a Danish startup specialising in rotor blade manufacturing for the wind energy industry. We do this with a unique approach using titanium 3d printing.
Titanium with its high performance properties and sublime reusability is a material that we believe holds the key to produce the next generation of wind turbines in combination with 3d printing technology.
The problem we are committed to solve
Current methods of harvesting energy from the wind have a huge flaw when it comes to reusability of materials: Here the rotor blades are primarily made from composites of glass fiber. The strong matrix structure within the composites also makes them very hard to separate into individual components upon end of life, resulting in very poor reusability.
There are currently no cost effective solutions to up-cycle composite materials of this scale. The consequence is that the majority of current wind turbine blades end up in land field deposits.
A rotor blade made from titanium would on the other hand be 100% recyclable.
Our mission
TOX-Rotorblades is on a mission to transform the wind energy industry to become truly sustainable. We do this by carefully selecting materials and manufacturing methods that fit into a circular economic model. The health of the planet and its living beings is one of the key aspects that the core of our start-up is built upon, and we are committed to provide a better future for everyone through honest and transparent actions in collaboration with our customers and partners.
Titanium is the 9th most abundant element in the earth's crust where it makes up about 0.57% by mass. After aluminium (8.2%), iron (5.2%) and magnesium (2.1%) it is the 4th most abundant structural metal. It can be considered plentiful, but the demanding processing of turning it into metal has given it a relatively high price tag, thus limiting its use for special applications.
Titanium is primarily found in the minerals rutile (TiO2), ilmenite (FeTiO3) and sphene (CaTiSiO5).
Processing of naturally occurring minerals into titanium metal is commercially done via the Kroll process.
Manufacturing of titanium metal
The Kroll process is a multiple-stage process where the ore is first oxidized using chlorine at temperatures of 1000 deg. C. The intermediate is then reduced using magnesium in an atmosphere of argon at 1000 deg. C.
This produces a titanium “sponge” that is processed in numerous ways including Vacuum Arc Remelting (VAR) and Electron Beam Cold Hearth Remelting (EBCHR) depending on the application of the final product.
Properties and applications of titanium
Titanium is known for its high strength to weight ratio. It is as strong as steel but weighs just 55% that of steel. This makes it a preferred choice in application where weight saving is an important factor.
Titanium also exhibits strong corrosion resistance. This makes it a widely used material in environments where corrosion is a concern, including sea water.
The properties of titanium make it a particularly interesting material of choice for wind turbine blades. Weight saving while maintaining strength increases the efficiency of the turbine, and the harsh environment of seawater will be home to an increasing number of wind turbines with Denmark alone planning to produce 6-7 GW of energy in the North and Baltic Sea.
Metal 3d printing is a relatively new manufacturing method that since its commercial birth in 1995 has seen an ever increasing growth due to its formidable ability to produce metal parts with complex geometries that require strength and lightness.
The exceptional design freedom of metal 3d printing makes it really interesting in regards to production of wind turbine blades. Wind turbine blades have a complex three-dimensional geometry that changes from a circular cross-section at the attachment point, which then transitions to an aerofoil in the mid-section.
Weight optimisation of the blade is also superior with 3d printing technology. Being able to create internal channels and spaces within the structure allows weight savings of up to 66% while maintaining strength.
A significant advantage of the technology is the high efficiency of utilisation of the material. Compared to traditional methods like CNC in which waste generation can reach 90% of the starting material, 3d printing produces only about 5% waste.
Mikael Eriksen
Mikael has more than 30 years of experience in the metal industry where he has worked with customers within the sectors of telecommunication, automotive and energy. He has been leading several projects where the use of new materials and processes has been a key focus.
“Innovation is what drives me. I find it greatly rewarding to apply my knowledge to create and develop solutions in collaboration with a strong team. I believe that TOX-Rotorblades will be a significant contributor to pushing the wind energy industry towards a level of sustainability at its highest”.
- Mikael Eriksen
Professor Christian Sonne
Professor Sonne’s background as a veterinarian along with his broad interests within the field of Environmental Sciences has enabled him to become one of the international leading scientists and authorities within Arctic Wildlife Toxicology.
Professor Sonne has a unique ability to collaborate with scientists from many fields within Environmental Sciences. This has enabled him to produce novel and cutting-edge research within Arctic wildlife toxicology, research that has very high applied and societal value across the Global Goals.
His research has contributed significantly to identify the presence of toxic man-made chemicals in Arctic and Baltic biota, and to identify the harmful effects of these on wildlife, ranging from the individual (organismal) level to the full scale of ecosystems.
His research has also contributed to the understanding of how indigenous people and communities are affected by man-made pollutants through dietary intake. The data provided has been significant for including several toxic man-made persistent organic pollutants in the Stockholm Convention as well as contributing to build guidelines for safe consumption of traditional food amongst Northerners.
Recently he has also begun working with sustainable materials and renewable energy.
”Climate change is the main driver of ecosystem and habitat deterioration, pollution and infectious diseases. I think that alleviating emissions of greenhouse gases using sustainable and recyclable materials to mitigate climate change and global warming is utmost important to ensure future global health”.
- Professor Christian Sonne
Tox-rotorblades is working closely together with several partners to develop and optimise titanium 3d printed wind turbine blades.
Our partners include:
Arc Additive Limited
Technical University of Denmark
mike@tox-rotorblades.com
cs@ecos.au.dk