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Spare Parts for Wind Turbines in the Late Operational Phase

18 Nov 2025

As wind turbines age, their failure rates increase systematically—a behaviour well described by the bathtub curve. In the wear-out phase of the operational lifecycle, this leads to a significantly higher demand for spare parts to support operation and maintenance activities. At the same time, OEMs are shifting their focus to newer turbine generations, making spare parts supply for legacy models increasingly challenging.

The second half of a turbine’s service life is of growing technical and economic relevance, as operators seek to maintain reliability and cost-efficiency. Additive Manufacturing (AM) presents a technically viable and economically promising alternative to conventional spare parts sourcing—particularly for components made of steel, cast materials, or polymers. However, challenges remain, especially regarding the dynamic loading of safety-critical parts and the legal framework surrounding the reproduction of existing turbine components.

A case study of a 250 kg cast steel component illustrates both the technical feasibility and the current legal boundaries of AM applications in the context of aging wind turbine fleets.

Speaker: Thomas Müller, Production Engineer – Digital & Innovation, EnBW Energie Baden-Württemberg AG

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Spare Parts for Wind Turbines in the Late Operational Phase

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