Lightning No Match for Wind Turbine Blade Protection System
Standing hundreds of feet above ground, wind turbines — like tall trees, buildings, and telephone poles — are easy targets for lightning. Just by virtue of their height, they will get struck.
Lightning protection systems exist for conventional wind turbine blades. But protection was needed for blades made from a new type of material—thermoplastic resin composites — and manufactured using an innovative thermal (heat-based) welding process developed by scientists at the National Renewable Energy Laboratory (NREL).
Thermoplastic materials, like plastic bottles, can be more easily recycled than the thermoset materials commonly used to make wind turbine blades today. While thermoset materials need to be heated to cure, thermoplastics cure at room temperature, which reduces both blade manufacturing times and costs.
NREL’s patent-pending thermal welding process for thermoplastic blades allows for these benefits and even adds to them by replacing the adhesives currently used to bond blade components. The use of welding instead of adhesives eliminates the downsides of added weight and cracking potential.
While thermal welding offers benefits, it also requires adding within the blade a metal heating element — which can attract lightning. As a result, a team of NREL researchers led by Robynne Murray and supported by General Electric (GE) and LM Wind Power (a GE subsidiary) invented a new lightning protection system to keep the novel thermoplastic materials safe.
Thermal Welding Goes for the Patent
In 2018, Robynne Murray, an NREL engineer who specializes in advanced manufacturing methods and materials for wind turbine blades, received a two-year NREL Laboratory Directed Research and Development award to research thermal welding of thermoplastic wind turbine blades.
To make one of these new blades, a vacuum pulls liquid thermoplastic resin into the fiberglass material that is placed in a mold for each blade half. To weld the blade halves together, scientists sandwich a conductive material — such as an expanded metal foil or carbon fiber — between the two blade components and attach a wire to a power source. This creates the heating element. As current flows through this element, the thermoplastic materials melt. Once they are melted, the current is switched off and the bond cools under pressure.
Murray’s research demonstrated that thermal welding can effectively bond thermoplastic wind turbine blade segments. She submitted a patent application on the process in 2018.
A Pathway for Lightning
Thermal welding works. But it leaves the conductive heating element, which can attract lightning, within the blade.
“Thermal welding is an important step in the progression of commercializing thermoplastic materials for wind blades, but what happens when lightning strikes a thermal-welded blade? That was an unanswered question and a big concern,” Murray said. “For thermal welding of thermoplastic blades to become commercially viable, it is critical that the conductive bond lines be protected from a lightning strike.”
Partnering with GE and LM Wind Power, Murray submitted a research proposal to the U.S. Department of Energy’s (DOE’s) Technology Commercialization Fund (TCF). TCF awards are designed to advance technology developed at national laboratories toward commercialization while encouraging lab-industry partnerships.
“With our partnership with GE, a company that can take the thermal welding process to commercialization, our TCF was a strong proposal,” Murray said. “Together, we wanted to determine whether we can protect these blades from lightning strikes and eliminate a big reason to stop us from using the technology.”
In 2019, the team received $150,000 in TCF funding; GE matched that amount.
The research partners set up shop in NREL’s Composites Manufacturing Education and Technology (CoMET) Facility to demonstrate that thermoplastic blades sealed using thermal welding can be protected from lightning strikes.
The team infused an expanded aluminum foil into the blade skin to divert lightning current away from the metal heating elements. They then completed experiments using a simulation that showed that a lightning strike would not cause blade failure with the lightning protection system in place.
Lightning protection To build a lightning shield for their innovative wind turbine blade design, the research team added an expanded aluminum foil layer (left) and a carbon-fiber heating element at the bond lines (right) to enable thermal welding of the blade parts. Photos by NREL
Lightning strike. Researchers used a lightning simulation technique to see where lightning might strike the blade and found that, typically, electricity hit the tip of the blade or one of the edges—but not inside the blade or welded seams where it could cause excessive damage. Photo by NREL
Physical damage tests — which subject the blades to high currents of electricity — demonstrated that about 80% of the electric current went into the expanded aluminum foil layer for lightning protection and not into the blade skin. The carbon fiber beneath the damaged area of the tip was also unscathed.
The research confirmed the design can protect wind turbine blades against failure caused by lightning strikes.
“LM Wind Power and GE Research were excited to work with NREL on the development of this technology and appreciated the support by DOE’s Technology Commercialization Fund. Thermal welding technology for thermoplastic, recyclable wind blades offers a significant opportunity to impact the sustainability and carbon footprint of wind blade structures,” said James Martin, director of blade platform deployment for LM Wind Power. “NREL’s focus on mitigating the lightning damage risks associated with the electrically conductive elements in the welded bond is a key challenge to be overcome, and their work has helped mature the technology toward potential commercialization.”
Still More Questions To Answer
The project has already delivered two strikes against lightning. Murray’s work developing a market-ready thermal welding system, however, is still at bat.
“We answered the question about lightning. But there are more questions to answer and more work to be done,” Murray said. “The next step for us is to do structural validation of thermally welded blade bond lines and blade tip segments. I hope we can do this in the next year or so.”
Read more about this project in Wind Engineering.
Article courtesy of NREL.
Electric motorcycles are already known for their instant torque and quiet performance, but now one electric dirt bike has proven it can do something gas bikes can’t: breathe where combustion engines can’t. Stark Future and Swiss mountaineer-rider Jiri Zak just made history by setting a new high-altitude world record on the world’s highest active volcano, riding a fully electric Stark VARG EX up to an astonishing 6,721 meters (22,051 feet) above sea level.
The record-setting ride took place on Los Ojos del Salado, a massive stratovolcano straddling the Chile–Argentina border in the Atacama Desert. It’s the tallest active volcano in the world and one of the most brutal environments on Earth to test the limits of man and machine. Sub-zero temperatures, violent weather, thin air, and volcanic terrain have made it the proving ground for record-breaking attempts by companies like Porsche, Yamaha, and Jeep since the early 2000s.
But this time, it wasn’t a combustion engine motorcycle powering the ascent, but rather a battery-powered motorcycle.
Stark’s electric VARG EX conquers the thin air
Riding at nearly 7,000 meters means serious altitude sickness risks for humans – and serious performance losses for gas engines. But that’s exactly where the Stark VARG EX shines. Without relying on air-fuel combustion, the VARG EX can deliver full torque even in oxygen-starved conditions. It also simplifies high-altitude riding by eliminating gear shifting, relying instead on electric driveline efficiency and seamless power delivery.
Jiri Zak, the expedition’s lead rider and a seasoned alpinist, put it best. “Two years ago this was just a dream – do it on an electric bike, where combustion loses its breath. Ojos is unforgiving; one mistake can cost your life. That’s why I’m here with a team I trust and a motorcycle that keeps delivering power in thin air.”
Zak’s attempt was logged on November 30, 2025, with GPS units that were sealed in advance to ensure authenticity. The full data is now undergoing third-party verification, with Guinness World Records authentication in process.
Stark and Zak aimed to push a motorcycle – regardless of the powertrain, electric or gas – higher than ever before. And they did.
The previous high-altitude motorcycling records involved heavily modified combustion bikes operating at the ragged edge of their capability. But the Stark VARG EX performed the feat right out of the box, with no major mechanical changes. That’s a serious milestone for electric mobility.
“This was never about a standalone number,” said Stark Future CEO Anton Wass. “It’s about proving that electric is not a compromise; it takes you further than any other combustion bike could. The VARG platform can operate at the edge of the atmosphere.”
Built for the extremes
To make the record possible, Stark assembled a team of logistics experts, mountain safety personnel, and videographers to document the expedition. The crew spent multiple days acclimating, scouting line choices, and studying energy management strategies for the high-altitude ride.
Weather windows were tight. Battery thermal regulation was crucial. Traction was unpredictable. Zak even described one of the most intense moments on the mountain, returning from the summit, “The hardest moment was the traverse to Argentina Pass. The balcony was gone. The wind and snow had erased my old track. Nature had taken the path back.”
Even with the challenges, the VARG EX maintained its composure, and its performance, throughout the climb.
A moonshot mentality
With a slogan like “Next stop? The moon!” it’s clear Stark is doing more than just chasing off-road trophies. The company is positioning itself as a symbol of what electric powertrains can accomplish in terrain where gas bikes falter.
Stark Future, founded in 2020 in Barcelona, has rapidly become the most talked-about name in the electric motocross scene. Their flagship VARG model claims to be the most powerful motocross bike ever built, and the EX variant used in this record attempt is the company’s enduro-specific version.
Stark’s vision is about pushing the motorcycle industry toward a more sustainable, electric future. And with this record-setting ride, they’ve just planted an electric flag higher than any motorcycle has ever gone before.
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The US solar industry just delivered another huge quarter, installing 11.7 gigawatts (GW) of new capacity in Q3 2025. That makes it the third-largest quarter on record and pushes total solar additions this year past 30 GW – despite the Trump administration’s efforts to kneecap clean energy.
According to the new “US Solar Market Insight Q4 2025” report from Solar Energy Industries Association (SEIA) and Wood Mackenzie, 85% of all new power added to the grid during the first nine months of the Trump administration came from solar and storage. And here’s the twist: Most of that growth – 73% – happened in red states.
Eight of the top 10 states for new installations fall into that category, including Texas, Indiana, Florida, Arizona, Ohio, Utah, Kentucky, and Arkansas. Utah jumped into the top 10 this quarter thanks to two big utility-scale projects totaling more than 1 GW.
But the report also flags major uncertainty ahead. Federal actions, including a July memo from the Department of the Interior (DOI), have slowed or stalled the approvals pipeline for utility-scale solar and storage. Without clarity on permitting timelines, Wood Mackenzie’s long-term utility-scale forecast through 2030 remains basically unchanged from last quarter.
“This record-setting quarter for solar deployment shows that the market is continuing to turn to solar to meet rising demand,” said Abigail Ross Hopper, SEIA’s president and CEO. She added that strong growth in red states underscores how decisively the market is shifting toward clean energy. “But unless this administration reverses course, the future of clean, affordable, and reliable solar and storage will be frozen by uncertainty, and Americans will continue to see their energy bills go up.”
Two new solar module factories opened this year in Louisiana and South Carolina, adding a combined 4.7 GW of capacity. That brings the total new US module manufacturing capacity added in 2025 to 17.7 GW. With a new wafer facility coming online in Michigan in Q3, the US can now produce every major component of the solar module supply chain.
“We expect 250 GW of solar to be installed from 2025 to 2030,” said Michelle Davis, head of solar research at Wood Mackenzie and lead author of the report. “But the US solar industry has more potential. With rising power demand across the country, solar could do even more if current constraints were eased.”
SEIA also noted that, following an analysis of EIA data, it found that more than 73 GW of solar projects across the US are stuck in permitting limbo and at risk of politically motivated delays or cancellations.
Read more: EIA: Solar + storage soar as fossil fuels stall through September 2025
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