One of the main issues related to the design and development of small wind turbines (SWTs) is the low Reynolds number. Operation in the transitory regime makes the rotor aerodynamic analysis a challenging task. Project GUST (Generative Urban Small Turbine) realized currently at the Institute of Turbomachinery (Lodz University of Technology, Poland) is devoted to the development of SWT (D = 1.6 m) for low-Reynolds number (low wind speed) flow conditions. The emphasis is on the blade design, aiming at improving the rotor aerodynamic efficiency. The paper will highlight the rotor design process, based on contemporary methods of experiment-simulation integration approach and use of rapid manufacturing techniques. In-house wind tunnel measurements of a scaled model performance were executed. A numerical analysis using dedicated software (QBlade) was conducted in parallel. A comparison between the obtained results indicated that the chosen numerical tools are capable of providing a reliable output, even in complex, transitional flow conditions. Bearing in mind the above observations, QBlade was incorporated into the development process of a completely new blade geometry which would increase rotor performance. The selected design has indeed prove to show better power outcome in an additional experimental campaign.

Small Wind Turbines (SWTs) are an increasingly developing Renewable Energy Source, thanks to the gradual popularisation of the prosumer energy generation approach. This, however, requires maximum safety of the machine, working next to households. Reliability is also necessary from the financial point of view, as SWTs should withstand 20 - 30 years of operation without any serious failure to ensure investment profitability. The weakest SWT element is arguably its most exposed one - the rotor - hence the important role played by the blade strength tests. The experimental analysis becomes preferable with increasing popularity of new materials (composites) and production techniques (additive manufacturing). This paper sets out to develop a test stand for static strength examination of 3D-printed SWT blades. This kind of objects is often considered as more vulnerable to structural failures than those created via machining techniques, due to their anisotropic structure, so ensuring structural integrity is crucial for safety reasons.