Plastics and Wind Power – Materials for the Energy of the Future

15 June is Global Wind Day – an international day of action that raises awareness of the potential of wind energy. And for good reason: in 2023, the mark of 1 terawatt of installed wind power was exceeded worldwide for the first time. In Europe, 139 million tonnes of CO₂ emissions were avoided thanks to wind energy. What is less well known is that this success would not be possible without plastics.

Today, wind power is one of the cheapest forms of electricity generation. In the EU, it already covers 20% of electricity demand – by 2050, this figure is set to rise to more than 50%. In addition to climate protection, the technology also brings economic growth: around 370,000 people work in the European wind sector, which contributes over 57 billion euros to value creation.

Whether rotor blades, nacelle cladding or cable insulation – plastics are indispensable in wind turbines. Fibre–reinforced plastics (FRP) in particular make a key contribution to performance: glass fibre-reinforced plastic (GRP) is standard, but carbon fibre-reinforced plastic (CFRP) is also increasingly being used – lighter and more stable at the same time.

Longer rotor blades mean a higher energy yield, but must also be light and resilient. This is where polymer-based lightweight construction scores highly. It enables aerodynamic shapes and reduces mechanical loads.

In addition, plastics have decisive properties for continuous operation in the open air. They are

• corrosion–resistant
• weatherproof
• versatile and mouldable

Wind turbines are exposed to extreme conditions – whether in the field or in the middle of the sea. Materials must be correspondingly versatile.

Onshore projects, for example in the Bavarian chemical triangle near Burghausen, require robust and easy–to–maintain systems. Plastic seals protect sensitive components from dirt and moisture.

Offshore plants, such as the planned Nordlicht 1 and 2 wind farms by BASF and Vattenfall in the North Sea, have to withstand wind, salt and UV radiation in the long term. CFRP and GFRP components are proving to be lightweight, durable and logistically advantageous here.

Small decentralised systems are also gaining in importance – such as mini wind turbines at BASF or E.ON. Their plastic components allow flexible designs and easy integration into existing infrastructures.

While around 80-90% of a wind turbine can be recycled, rotor blades remain problematic. They consist of complex composite materials – resins, fibres, fillers, cables – which are technically and economically complex to separate.

A survey by the Fraunhofer Institute for Chemical Technology (ICT) shows that the volume of dismantling is currently low: Currently, the volume of dismantling is low – many old plants are repaired or sold on. However, as turbines age and repowering increases, so does the need for disposal.

Some manufacturers such as Vestas and Siemens Gamesa are already developing fully recyclable rotor blades. The aim is to achieve waste-free wind power – a milestone on the way to a genuine circular economy.

The further development of wind energy goes hand in hand with advances in plastics technology. The focus is on thermoplastic composite materials that are easier to recycle, as well as bio-based resins and new fibre solutions.

Digital technologies such as AI-supported simulation and digital twins help to optimise designs and minimise the use of materials. At the same time, additive manufacturing improves prototyping and enables complex, functional designs – especially for smaller applications.

This results in material solutions that combine performance, sustainability and cost–effectiveness.

Wind power is a prime example of how crucial plastics are for the energy transition. They enable robust, efficient and sustainable energy systems – from megawatt farms to microturbines.

At the same time, the industry is faced with the task of establishing genuine recycling concepts for composite materials. 'Design for recycling' and functioning cycles are the key. The plastics industry has the opportunity to position itself as a pioneer of sustainable technologies.

Looking ahead to Global Wind Day, it is clear that wind power is not just a symbol of renewable energy – it is also a testing ground for sustainable material applications. And plastics play a key role in this.