Generative design and additive manufacturing techniques on the optimization of multi-MW offshore direct-drive wind turbine electrical generators

New advances in structural optimization techniques and manufacturing methods, such as generative design (GD) and additive manufacturing (AM), are revolutionizing the capabilities to generate high-efficiency and lightweight models in comparison with conventional processes. This study addresses a structural optimization strategy for offshore wind turbine direct-drive generator structures using generative design (GD) and additive manufacturing (AM) techniques. The use of multi-objectives structural optimization processes using GD techniques allows for the exploration of a wide number of unconventional topologies on a tailored, fit-for-purpose strategy, and the implementation of AM methods makes possible the fabrication of complex designs with metallic and composite materials. GD and AM represent a revolution in the field of design optimization, offering flexibility and adaptability while collecting a vast amount of structural analysis data, crucial for a cost-effective approach in the early stages of design projects. The implementation of these techniques demonstrated over 7% weight reduction, a 40% increase in operational range, and a decrease in the cost of manufacturing.