The main structure utilizes glass fiber-reinforced epoxy resin, while load-bearing components-such as spar caps-employ carbon fiber laminated composites capable of achieving a tensile strength of 1200–1500 MPa. To withstand high-temperature operating conditions of 800°C, the first-stage blade component is made of high-temperature resistant material (steel or cast iron), whereas the second component utilizes a low-cost material (plastic); thermal isolation is achieved through a designed gap.
The lightning protection system receptors are fabricated from TC4 titanium alloy (conductivity: 3.5% IACS); the receptor tip extension is designed with a length of 10–70 mm, maintaining a 5–20 mm gap from the conductive extension [9]. Shear webs feature a 3D-printed lattice structure, with porosity controlled between 15% and 25% to balance strength and weight.
Damaged rotor blades can be repaired using laser solid forming technology. The performance of repaired blades meets or even exceeds the standards for new blades, while repair costs amount to only 20% of the cost of manufacturing a new blade, thereby effectively enhancing economic efficiency and reliability.
