EDWIM · Energy Dense Wind powertrains through sustainable Innovative Manufacturing

The EDWIM project aims to introduce a digitalised, high-performance and sustainable production model for the most critical powertrain elements: gearbox ring gears and generator stators. These components directly impact reliability, efficiency, and operational costs of wind energy, particularly in large-scale and offshore installations.EDWIM will combine process innovations with a common digital architecture based on simulation models, Digital Twins (DTs) and intelligent Recommendation Systems (RS). This approach will enable virtual simulation of manufacturing processes, accurate process monitoring and product quality assessment as well as process design optimisation, reducing the reliance on empirical methods and costly trial-and-error prototyping. For gearboxes, EDWIM will replace conventional furnace-based treatments with an electrified induction hardening process supported by advanced raw material design, additive-manufactured inductors and automated handling systems. For generators, it will introduce a fully automated stator insulation process based on bio-based tapes and low-VOC resins, supported by DT-enabled monitoring and advanced NDTs. By demonstrating its solutions in two industrial pilot lines, measurable reductions will be achieved in process time, energy and material consumption and pollutants emissions, and in components´ durability and reliability. EDWIM also integrates gender-inclusive design and advanced training for operators, improving health, safety and digital skills across the workforce.By reducing manufacturing costs, extending turbine reliability and increasing process sustainability, EDWIM contributes directly to the EU Green Deal, the Industrial Strategy and the Strategic Energy Technology (SET) Plan. The project will reinforce Europe’s leadership in clean, digitalised manufacturing, set new standards for advanced production, and enhance the competitiveness of the European wind energy supply chain against global competitors.