Blade Bonding Solutions

Collaboration in manufacturing is vital, particularly in the wind energy sector, where the scale and complexity of turbine blade production demand both technical expertise and operational agility. Faced with the challenge of improving blade bonding reliability and enhancing supply chain efficiency, Nordex Group turned to Sika for a tailored solution. This partnership was shaped not only by a shared focus on quality but also by the ability to adapt, test, and implement new materials and processes in response to market demands. 

The journey began with a market-driven need for backup sourcing and improved performance. For years, Nordex had relied on a single supplier for blade bonding paste, but changing requirements called for alternatives that could meet rigorous engineering specifications and support multi-site manufacturing. Sika introduced SikaPower®-830, a globally DNV-certified epoxy bonding paste with local production capacity, helping Nordex reduce risk and meet local content requirements in their supply network. 

From the outset, the project emphasized hands-on cooperation. Teams launched extensive laboratory qualification work, assessing the adhesive for properties such as curing behavior and material compatibility. This step-by-step approach built trust, ensuring that any scaled production would be grounded in solid technical validation. Progress led to full-scale blade manufacturing trials at Nordex’s Lumbier facility in Spain, a site selected for its close proximity to Sika’s central European production as well as its strategic importance for the N163 blade model. 

Sika’s technical experts were on-site throughout, supporting Nordex with process integration and troubleshooting. Early in the rollout, differences in material properties became apparent—SikaPower®-830 is glass fiber-free and exhibits a lower density than conventional products, which impacts both handling and weight calculations. Plant engineers and Sika specialists collaborated closely, observing batch performance, refining mixing protocols, and adjusting mold scrapping techniques to the adhesive’s flow characteristics. When residual material overflow presented a challenge, Sika adapted the formulation and jointly revisited production schedules with Nordex’s team, demonstrating the kind of flexible support that can only come from a direct partnership. 

Following success in Spain, the initiative shifted to China, where Nordex’s blade partner agreed to participate in broader evaluations. Here, a key advantage emerged: Sika’s regional manufacturing allowed for responsive supply and localized engineering support. Trials on the N175 blade type highlighted the adhesive’s versatility, and Nordex’s confidence grew as consistent results were observed across both German and Chinese facilities. Knowledge sharing between these sites was critical – Nordex leveraged insights from the initial trials to standardize application and ensure a uniform process globally. 

Throughout, operational benefits went beyond initial expectations. Consumption of bonding paste decreased due to the product’s lower density, helping manage costs. The fast build up of glass transition temperature, observed during processing, opened the door to potential cycle time reductions – enabling teams to test faster curing, save energy, and boost output without compromising reliability. Working side-by-side with Sika, Nordex plant engineers realized hidden efficiencies and established best practices that could be extended across future projects. 

Looking ahead, the partnership between Sika and Nordex continues to center on technical progress, improved process stability, and exploring new adhesive technologies. Through close collaboration and knowledge-sharing — from qualification to full market rollout — Sika and Nordex aim to further optimize performance and production resilience in the wind turbine sector, moving the industry forward together.