Semi-Automated Manufacturing Blade Approach

SAMBA (Semi-Automated Manufacturing Blade Approach) delivers a transformative leap in wind turbine blade manufacturing by integrating semi-automation, digital quality assurance, and advanced materials into a scalable pilot line. As Europe targets 500 GW wind capacity by 2030, SAMBA addresses the urgent need for high-throughput, defect-free blade production. The project pioneers four innovation streams: (1) automated ply kitting and stacking to reduce ergonomic risks and improve layup precision; (2) intelligent pick-and-place systems for distortion-free mould placement; (3) digital assurance using AI-enabled defect detection and process modelling; and (4) advanced preforms with automated ply scarfing for improved drapability and joint integrity. These innovations will be validated on a 40 m blade span of the V236 platform at Vestas’ Isle of Wight facility, demonstrating industrial relevance and readiness at TRL 6.SAMBA’s impacts span productivity, safety, sustainability, and competitiveness. It targets ≥50% cycle time reduction, ≥95% first-pass yield, and ≥5% unit cost savings, while reducing manual handling by ≥70% and aerosol exposure by ≥90%. Environmental benefits include ≥25% GHG reduction and ≥90% hardware reuse. The project supports the EU Net Zero Industry Act by enabling clean-tech manufacturing in Europe and strengthening strategic autonomy. The consortium unites nine partners across six countries: two large enterprises (Vestas, Owens Corning), two SMEs (Envisma, Vivid Components), three RTOs (NCC, Tecnalia, Arditec), and two RPOs (DTU, University of Bristol). This interdisciplinary team spans manufacturing, robotics, materials science, AI, and sustainability, ensuring robust innovation and exploitation. SAMBA will deliver 13 Key Exploitable Results, a full-scale demonstrator, and a roadmap for industrial deployment, positioning Europe at the forefront of sustainable wind energy manufacturing.