The RENEWEDGE project, coordinated by Aerox the Universidad CEU Cardenal Herrera and AIMPLAS, is led by Prof Fernando Sánchez, Director of IDIT at CEU UCH, with researchers Luis Doménech and Aurelio Olivares also participating.
Rain-induced erosion caused on the leading edge of wind turbine blades is one of the greatest technological challenges facing the wind-power industry. It affects both onshore and offshore wind turbines and the problem has become more severe with the arrival of new-generation blades. These are longer and operate at higher speeds, increasing the intensity of impacts from droplets, particles, and hail. This damage results in a loss of aerodynamic efficiency and, consequently, a significant reduction in annual energy production, as well as high inspection and repair costs.
Commercial leading edge protection (LEP) systems for blades, typically formulated with petrochemical-based polyurethanes, no longer offer the level of performance required by the new generation of turbines. At the same time, there is mounting pressure within the sector to move towards materials with a lower environmental footprint that are more sustainable and aligned with circular‑economy principles. This combination of factors has led manufacturers and operators to demand innovative solutions that increase durability, reduce maintenance costs, and improve the sustainability of the blades’ life cycle.
Potential of bio-polyols
For the RENEWEDGE project, Aerox, the Universidad CEU Cardenal Herrera University (CEU UCH), and the AIMPLAS Plastics Technology Centre are working on a new LEP system comprising a filler and a polymeric coating formulated using raw materials from renewable sources. The project will investigate the potential of bio‑polyols to fully or partially replace traditional fossil‑based components, with the aim of achieving mechanical, elastomeric and resistance properties equal to or better than those currently available. To this end, the relationship between the chemical structure of the bio‑polyol and the final performance of the coating will be analysed in detail, ensuring a solution that is competitive from a technical, financial and environmental standpoint.
As highlighted by Aerox, “currently there is no commercially available bio-based LEP system that meets the stringent requirements of the wind-power industry. With RENEWEDGE, we are taking a leap forward towards a new generation of leading-edge protection systems. Our goal is to formulate a bio-based LEP that matches or improves the performance of current solutions, but with a clear focus on the sustainability and durability required for the future of the wind-power sector.”
The RENEWEDGE project aims to create a new generation of sustainable coatings to protect the leading edge of wind turbine blades against rain and hail impacts
Computational prediction for the wind-power sector
One of the most innovative parts of the project is the development of a computational tool capable of reliably predicting the progression of erosion damage during the service life of the blades. This system will combine traditional physical modelling of droplet impact with topological data analysis (TDA) techniques to extract and characterize the geometric evolution of damage from experimental tests. Machine learning models trained on these metrics will then be incorporated, allowing estimates to be refined and critical material points to be anticipated. This hybrid approach will provide a predictive solution for maintenance planning, blade performance optimization, and the reduction of operational uncertainty.
As noted by Prof Fernando Sánchez, Director of IDIT (the Institute of Design, Innovation and Technology) at CEU UCH and Lead Researcher of RENEWEDGE, “the project is a chance to make progress in a key area for the industry: estimating the real progression of erosion damage. Combining experimental data with topological data analysis and machine learning techniques offers a unique opportunity to improve predictions of material behaviour under real operating conditions.” CEU UCH researchers Luis Doménech and Aurelio Olivares are also involved in the RENEWEDGE project.
New materials: efficient and more sustainable
The research also includes a comprehensive analysis of the materials and processes involved in the development of the new LEP system, in order to ensure not only its sound technical performance but also its alignment with sustainability principles. This will include the assessment of the environmental impact through life-cycle analysis, economic viability via cost cycle analysis, and the social impact associated with the use of the new materials. In addition, in line with European Union strategic guidelines, the project includes a theoretical study of a digital product passport, aimed at ensuring traceability and facilitating future integration into a more transparent and regulated market.
“We want to ensure that the new LEP system is developed according to safe and sustainable by design (SSbD) criteria from the outset, and to assess its environmental impact. Additionally, we are working on the requirements for its digital passport, which will be essential for its integration into a more traceable and regulated market in the future,” added María Llácer, a circular economy researcher at AIMPLAS.
The new solutions will increase blade durability, reduce maintenance costs, and improve operational planning, contributing to more efficient and sustainable generation of wind energy
IVACE+i and FEDER funding
Advances in bio-based materials and predictive tools will enable blade manufacturers to access more durable and environmentally friendly solutions. Operators will be able to reduce costs associated with maintenance and unscheduled downtimes, while wind farm developers will benefit from greater certainty in investment planning. Moreover, the proposed approach will facilitate better management of turbine service life, making energy generation in this way more reliable and sustainable.
This project is funded by the Valencian Institute of Business Competitiveness and Innovation (IVACE+i), through the Strategic Cooperation Projects programme under its 2024 call, and by ERDF funds. Specifically, the Valencian Innovation Agency (AVI) (IVACE+i Innovation), within the framework of the Strategic Cooperation Projects Programme grants aimed at strengthening and developing the Valencian Innovation System to improve the productive model for the 2024–2026 period, has awarded €220,892.27 to CEU Cardenal Herrera University to develop the RENEWEDGE project, “Protection system for the leading edge of wind turbine blades based on raw materials of renewable origin” (INNEST/2024/47).
About the IDIT at CEU UCH
IDIT (the Institute of Design, Innovation and Technology) is one of the research institutes of the Universidad CEU Cardenal Herrera (CEU UCH) in Valencia. Founded in 2004 within the ESET , the University’s School of Architecture, Engineering and Design (ESET), which offers a range undergraduate and postgraduate programmes, the IDIT at CEU UCH is led by Prof Fernando Sánchez López. IDIT’s mission is to promote research activity and innovation, focusing its efforts on the development of competitive projects linked to industry and other research institutions.
