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Wind turbine blades might look elegant, even ballet-like, as they glide through the air. But, much like ballet, achieving that simple grace requires complex, advanced engineering.

NREL researchers build a 13-m thermoplastic blade at NREL’s CoMET facility. Photo from the National Wind Technology Center at the NREL Flatirons Campus. (Photo by Ryan Beach / NREL)

A team of National Renewable Energy Laboratory (NREL) researchers are furthering their revolutionary combination of recyclable thermoplastics and additive manufacturing (better known as three-dimensional [3D] printing) to manufacture advanced wind turbine blades. The advance was made possible by funding from the U.S. Department of Energy’s Advanced Manufacturing Office—awards designed to stimulate technology innovation, improve the energy productivity of American manufacturing, and enable the manufacturing of cutting-edge products in the United States.

Led by NREL senior wind technology engineer Derek Berry, the team’s novel techniques could revolutionize how wind turbine blades are manufactured.

Winds of Change

Today, most utility-scale wind turbine blades have the same clamshell design: two fiberglass blade skins are bonded together with adhesive and use one or several composite stiffening components called shear webs. This manufacturing process has been optimized for efficiency over the past 25 years—but, in reality, it has changed very little.

That needs to change.

To make wind turbine blades lighter, longer, less expensive, and more efficient at capturing wind energy—improvements critical to the Biden Administration’s goal to cut greenhouse gas emissions in part by increasing wind energy production—researchers must entirely rethink the conventional clamshell.

To start, the NREL team is focusing on the resin matrix material. Current designs rely on thermoset resin systems like epoxies, polyesters, and vinyl esters, polymers that, once cured, cross-link like brambles.

“Once you produce a blade with a thermoset resin system, you cannot reverse the process,” Berry said. “That makes the blade difficult to recycle.” As more and more wind turbines are installed every year, new wind turbine blades should be designed to be repurposed or even recycled to prevent them from undercutting the green economy they are meant to help build.

Different Materials, New Methods

Derek Berry and his team of NREL researchers did just that. Working with the Institute for Advanced Composites Manufacturing Innovation in NREL’s Composites Manufacturing Education and Technology (CoMET) Facility, the multi-institution team developed systems that use thermoplastics, which, unlike thermoset materials, can be heated to separate the original polymers, enabling end-of-life recyclability.

Thermoplastic blade parts can also be joined using a thermal welding process that could eliminate the need for adhesives—often heavy and expensive materials—further enhancing blade recyclability.

“With two thermoplastic blade components, you have the ability to bring them together and, through the application of heat and pressure, join them,” Berry said. “You cannot do that with thermoset materials.”

Moving forward, NREL, along with project partners TPI Composites, Additive Engineering Solutions, Ingersoll Machine Tools, Vanderbilt University, and the Institute for Advanced Composites Manufacturing Innovation, will develop innovative blade core structures to enable the cost-efficient production of high-performance, very long blades—well over 100 meters in length—that are relatively low weight.

By using 3D printing, the research team can produce the kinds of revolutionary designs needed to modernize turbine blades with highly engineered, net-shaped structural cores of varying densities and geometries between the structural skins of the turbine blade. The blade skins will be infused using a thermoplastic resin system.

If they succeed, the team will reduce turbine blade weight and cost by 10% (or more) and production cycle time by at least 15%, a huge leap (or pirouette) for wind energy technology.

In addition to the prime AMO FOA award for additively manufactured thermoplastic wind turbine blade structures, two subgrant projects will also explore advanced wind turbine manufacturing techniques. Colorado State University is leading a project that also uses 3D printing to make fiber-reinforced composites for novel internal wind blade structures, with Owens Corning, NREL, Arkema Inc., and Vestas Blades America as partners. The second project, led by GE Research, is dubbed AMERICA: Additive and Modular-Enabled Rotor Blades and Integrated Composites Assembly. Partnering with GE Research are Oak Ridge National Laboratory, NREL, LM Wind Power, and GE Renewable Energy.

Learn more about NREL’s advanced manufacturing and wind energy research and explore the CoMET capabilities.

Article courtesy of National Renewable Energy Laboratory (NREL).

 

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Hyundai Ioniq 9 first drive: Stylish SUV outside, spacious and versatile 3-row minivan inside

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Hyundai Ioniq 9 first drive: Stylish SUV outside, spacious and versatile 3-row minivan inside

Hyundai flew us out to Savannah, Georgia, a few weeks ago to get our first impressions of the much-anticipated Ioniq 9 three-row SUV. The vehicle uses the same E-GMP platform as the Kia EV9 and some smaller HMG EVs but the real question is: how is the Ioniq 9 different? Let’s take a look…

Size matters

This is a big EV with spacious three rows that seat six or seven adults comfortably. As far as I am concerned,the Ioniq 9 is Hyundai’s flagship vehicle.

The drive was similar to the Kia EV9, which is obviously a good thing. The big vehicle has solid electric acceleration, and Hyundai has done great work with the suspension to make this heavy car feel light on its toes. But Hyundai has made efforts to make the drive even smoother and quieter. The foam-filled tires, soft suspension, acoustic glass, and active noise cancellation all make the ride feel like floating rather than driving.

Front-row seats are not only spacious but also offer ample comfort and legroom. Also, there’s plenty of legroom in the second row (42.8 inches) and spacious third row (32.0 inches). Did I mention this is a big vehicle?

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What stands out to me on the interior is the flat floor enabled by the E-GMP battery and remarkably long wheelbase (3,130mm / 123.2 inches). It doesn’t feel like an SUV inside, it feels like a big minivan (oxymoron noted). While many folks are embarrassed to be seen in a minivan, nothing beats the configuration internally for trips and driving more than 4 people around – so the comparison is fully complimentary.

Hyundai obviously kitted us out with their top-end interiors, and they definitely felt sporty and luxurious.

Frunk

The Frunk o the Ioniq 9 isn’t anything to write home about and one of the few downsides to this vehicle. Hyundai of course says that their customers don’t want it, just like the bigger Frunk-maker’s say that their customers love it. For better or worse, it is a great place to put some charging cables, a tire inflator kit or some valuables but don’t expect it to be used frequently like a Tesla/Rivian or F-150/Silverado Frunk for groceries and general purpose cargo.

I really love the look of the Ioniq 9, which the company says is shaped like a sailboat hull with its big taper at the back. That also gives the Ioniq an otherworldly low drag coefficient of 0.259. That, along with the big 110kWh battery and Hyundai’s always efficient EVs, gets this thing to 335 miles for the RWD version. The performance AWD variant only drops down to 311 miles, a hit worth taking.

That range and the spacious interior mean that this is a great road trip EV. AWD versions can even tow up to 5000lbs. HMG’s software adjusts range predictions based on towing. Aerodynamics and efficiency of the trailer will all determine how much range is sacrificed but with over 300 miles to start with, odds are it will get you where you are towing.

NACS charging

The Ioniq 9 is one of the first non-Tesla EVs to come standard with a NACS charger, meaning it can natively charge at most Tesla Superchargers. Hyundai also includes an adapter so it can charge at CCS Combo stations and use a J-1772 Level1/2 charger.

Exterior

I am torn on the exterior look of the Ioniq 9. I love the shape, which Hyundai says is reminiscent of the aerodynamic hull of a sailing ship. I love the pixel lights that have become iconic in Hyundai’s EV lineup. Even the overall silhouette, something that Hyundai calls “Aerosthetic”—a harmonious blend of aerodynamics and aesthetics— is pretty incredible.

But I don’t love some of the design ornaments–like the cutout pieces over the front and back wheels. While I realize that seems like a nit-pick, I can’t unsee it. It is more subdued in the darker colors, however.

Pricing: starts at $58,955 for the RWD S trim and goes up to $76,490 for the Performance Calligraphy Design AWD trim. Eligible for $7500 Federal tax credit and various state/local and utility discounts.

Electrek’s take

I really love this take on the 3rd row electric SUV. Would I take the Ioniq 9 off-road like a Rivian? No. Does it accelerate like a Telsa Model X? No.

However, it does everything most third-row SUV owners expect, and it does it quietly and effortlessly. For those looking for a luxurious 3-row electric SUV with an interior that rivals the comfort of a minivan, you have to put the Hyundai Ioniq 9 at the top of your list.

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Honda pulls the plug on its larger electric SUV, but that’s not all

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Honda pulls the plug on its larger electric SUV, but that's not all

That larger Honda electric SUV may be a pipe dream after all. Honda follows Ford, Toyota, and other automakers in adjusting major EV plans in the US.

Honda scraps plans for a larger electric SUV

Although Honda’s first electric SUV, the Prologue, was one of the top-selling EVs in the US last year, the Japanese automaker is preparing for a slowdown.

Thanks to the Trump Administration’s recently passed “Big, Beautiful Bill,” which kills off the $7,500 federal tax credit at the end of September, Honda expects lower demand for EVs.

According to a new Nikkei report, Honda is now scrapping plans for its larger electric SUV in the US, its largest market. Instead, the company will focus on hybrid vehicles, similar to recent moves from Ford, Toyota, and others.

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Honda’s larger electric SUV was due to be released around 2027, about the same time as Ford and Toyota’s three-row EV SUVs. The upcoming Honda 0 Series electric SUV and sedan are still set to arrive starting next year.

We got a sneak peek of the midsize electric SUV in April after a camouflaged prototype made its debut on the streets of Tokyo for the first time.

Honda announced earlier this year that it is reducing its planned EV investments by $21 billion through 2030, as it expects lower demand. Like Ford and Toyota, Honda will focus on hybrids in the meantime.

Honda-larger-electric-SUV
Honda 0 SUV (Source: Honda)

In a separate report on June 20, Nikkei claimed that Honda and Nissan were considering a new US partnership just months after their global tie-up fell through.

Electrek’s Take

Honda is one of the few Japanese automakers to gain some momentum in the US EV market, but scrapping plans for the bigger model could put it behind rivals like Hyundai and Kia.

Through the first half of the year, Honda has sold over 16,300 Prologues in the US. In comparison, Toyota sold just over 9,200 bZ4X models.

Even Acura’s EV is seeing significantly more demand than expected. Acura sold 10,355 ZDX models in the first half of 2025, outpacing the Cadillac Lyriq, which is based on the same platform. Earlier this year, Mike Langel, vice president of national sales for Acura, told Automotive News that the company expected to sell around 1,000 ZDX models a month this year.

Honda, like most of the auto industry, is bracing for a shakeup as the Trump Administration rolls back EV incentives, putting the US on track to lag even further behind leaders like China.

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Paris’ popular bike share program has a big sticky finger problem

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Paris' popular bike share program has a big sticky finger problem

Paris’ bike-share system, Vélib has long been considered one of the shining success stories of urban micromobility. With a massive fleet of over 20,000 pedal and electric-assist bicycles around Paris, the service has helped millions of residents and tourists get around the City of Light without needing a car or scooter. But lately, a growing problem is threatening to knock the wheels off this urban mobility marvel: theft and joyriding.

According to city officials and the service operator, more than 600 Vélib bikes are now going missing every single week. That’s over 30 bikes a day simply vanishing from the system – some stolen outright, others taken on “joy rides” and never returned.

“At the moment we’re missing 3,000 bikes,” explained Sylvain Raifaud, head of the Agemob company that currently operates the Velib system. That’s nearly 15% of over 20,000 Vélib bikes across Paris.

The sticky-fingered culprits aren’t necessarily professional thieves or organized crime rings. Instead, they’re often regular users who treat the shared bikes like disposable toys.

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The city estimates that many people have figured out how to pry the bikes out of the system’s parking docks, unlocking one for a casual cruise and then ditching it somewhere far from a docking station.

Once pried free, the bikes are technically usable for the next 24 hours until their automatic locking feature kicks in. At that point, the bikes are often simply abandoned. Some end up in alleyways. Others get tossed in rivers. A few just disappear completely.

And since the bikes are intended to be parked at their many docking stations around the city, they don’t have GPS chips, further complicating recovery of “liberated” bikes.

The issue started small but has grown into more than an inconvenience – it’s beginning to undermine the entire purpose of the service. With bikes going missing at such a high rate, many Vélib docking stations are left empty, especially during rush hours.

Riders looking for a quick commute or a convenient hop across town are increasingly finding themselves without available bikes, or having to walk long distances to find a functioning one.

That kind of unreliability chips away at user confidence and threatens to drive potential riders back into cars, cabs, or other less sustainable forms of transport at a time when Paris has already made great strides to dramatically reduce car usage in the city.

The losses are financially painful, too. Replacing stolen or vandalized bikes isn’t cheap, and the resources spent on tracking down missing equipment or reinforcing anti-theft measures are stretching thin. Vélib has faced theft and vandalism issues before, especially during its early years, but this latest surge has officials sounding the alarm with renewed urgency.

Officials acknowledge that there’s no easy fix. Paris, like many cities with bike-share systems, walks a fine line between accessibility and accountability. Part of what makes Vélib so successful is its ease of use and widespread availability. But those same features make it vulnerable to misuse – especially when enforcement is limited and the consequences for abuse are minimal.

The timing of the problem is especially unfortunate. In recent years, Paris has seen impressive results in reducing car traffic, expanding bike lanes, and promoting cycling as a key part of its sustainable transport strategy. Vélib is a cornerstone of that plan. But if the system becomes too unreliable, it risks losing the very people it was designed to serve.

Meanwhile, as Parisians increasingly find themselves staring at empty docks, the challenge for the city and Vélib will be to restore confidence in the system without making it harder to use. That means striking the right balance between freedom and responsibility, between open access and protection against abuse.

In a city where cycling is supposed to be the future of mobility, losing thousands of bikes to joyriders and sticky fingers isn’t just frustrating; it’s unsustainable.

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