A multi-parametric composite approach for the optimization of wind turbine blades using Double-Double laminates

Abstract. As wind turbines scale to meet growing energy demands, blade structures face increasingly demanding performance requirements. This work addresses this challenge by extending the design space of composite blades through the substitution of traditional triaxial laminates with Double-Double (DD) laminates. While triaxial laminates are widely used due to their convenient layup and manufacturability, they are rarely scrutinized in literature and often lead to suboptimal structural performance. To enable this substitution, a multi-parametric composite modeling approach is developed and integrated into a gradient-based optimization framework. This architecture enables the coexistence of discrete and continuous laminate formulations within a single panel, allowing for detailed, skin-wise optimization of sandwich structures. The approach is applied to a modified blade design of the IEA-15-240 Reference Wind Turbine. Results demonstrate that DD laminates provide a more effective buckling-oriented design, resulting in significant mass savings in the shell structure.