In general, standard aerodynamic design is divided into two paths—numerical analysis and empirical tests. It is crucial to efficiently combine both approaches in order to entirely fulfill the requirements of the design process as well as the final product. An effective use of computational analysis is a challenge, however it can significantly improve understanding, exploring and confining the search for optimal product solutions. The article focuses on a rapid prototyping and testing procedure proposed and employed at the Institute of Turbomachinery, Lodz University of Technology (IMP TUL). This so called Fast Track approach combines preparation of numerical models of a wind turbine rotor, manufacturing of its geometry by means of a 3D printing method and testing it in an in-house wind tunnel. The idea is to perform the entire procedure in 24 h. The proposed process allows one to determine the most auspicious sets of rotor blades within a short time. Owing to this, it significantly reduces the amount of individual subsequent examinations. Having fixed the initial procedure, it is possible to expand research on the singled-out geometries. The abovementioned observations and the presented overview of the literature on uses of 3D printing in aerodynamic testing prove rapid prototyping as an innovative and widely-applicable method, significantly changing our approach to experimental aerodynamics.

Increasing popularity of individualised electricity generation from wind by prosumers creates a strong demand for profitable and highly efficient small wind turbines. This paper investigates the influence of rotor blade solidity parameter on device efficiency in hope of determining its optimal value as a part of the development process of the GUST small wind turbine. The study involved experimental analysis in the wind tunnel and numerical simulations performed in QBlade software. Different solidities of the rotor were achieved by alteration of (1) number of blades and (2) chord distribution along the blade span. The increase of rotor solidity resulted in augmentation of the aerodynamic efficiency in both approaches. The elongation of the chord by 33% in a 3-bladed rotor resulted in a bigger power coefficient increment than addition of a 4th blade with original chord distribution. Even though the solidity was the same, the 3-bladed rotor performed better, possibly due to lower form drag. The results emphasize the importance of the rotor solidity optimization during the small wind turbine rotor development and may significantly influence overall power output.

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) can be significantly sensitive to variances in the blade geometry shape when their operation in relatively low ranges of Reynolds numbers is considered. An SWT case study, where an existing wind turbine prototype was equipped with a redesigned blade set, to increase its aerodynamic efficiency, is presented. The geometry modification process was targeted at maximizing the turbine power coefficient in the presumed point of low Reynolds operation. The applied design and analysis methods included practical implementation of previously established “Fast Track” procedure for wind turbine development. A newly prepared blade geometry and a reference blade set were examined numerically and experimentally. Selected design and assessment processes were supposed to be low resource demanding, making them possibly highly applicable in renewable energy industry. Therefore, the numerical analysis of both geometries was based on BEM (blade element momentum theory) equations. The research was expanded by model validation in small-scale wind tunnel tests to provide detailed information on BEM data reliability in comparison to the results of the experiment. The small-scale analysis, performed in Reynolds numbers below 100,000, provided information sufficient for evaluation of the redesigned blade. Implementation of the geometry obtained throughout the proposed procedure increased the rotor’s maximum power coefficient by 10%.

One of the increasingly important criteria, when constructing a Small Wind Turbine (SWT), is its sustainable design. It means constructing the SWT in such a way that it can provide a cheap, easy and safe access to clean energy at a specific location for predicted number of consumers. This paper highlights three issues. First, benefits from the application of the rapid prototyping technology are discussed. 3D printers can be used as a durable and relatively cheap means of SWT components production. Also, the possibility of using recycled plastic for 3D-printed components is of big importance. Secondly, the modular construction of the small wind turbine is outlined. This facilitates the product versatility, proneness to adjustments and ease of maintenance. Last but not least, the production costs for individual units as well as multi-unit production are reviewed to show the financial benefits of SWTs and the payback of such investments over the years. The article concludes with a set of recommendations for wind turbine design, conformal with the suggestions of the UN Sustainability Report and Sustainable Development Goal 7.1. The utilization of described concepts is demonstrated basing on the GUST 1.6 m diameter horizontal axis SWT.