CNC machining blade root on-site. Source (All Images) | We4Ce and CNC Onsite

Dutch rotor blade expert We4Ce (Almelo, Netherlands) and Danish precision machining specialist CNC Onsite (Veijle) have completed a joint project to transfer blade repair expertise to a wind park in South Asia. In May 2025, the companies trained the customer’s technicians to independently repair loose blade root bushings on 26 turbines — marking the first in-field use of the partners’ new remanufacturing method. The approach offers a cost-effective, sustainable alternative to full blade replacement by eliminating the need for off-site transport and reducing blade waste.

The blade root bushing, or insert, is a safety-critical component that connects the rotor blade to the turbine hub. In some blades, polyester resin is used to embed the bushing, though it is more sensitive to shrinkage than epoxy resin. For example, a higher volume of resin between the unidirectional bar and bushing shrink more than thin layers. This inconsistent shrinkage in thin layers, especially between the root laminate and bushing, can lead to the formation of microcracks, reducing the bonding surface and increasing the risk of the bushing loosening, potentially leading to blade failure.