Beyond the Surface: How Deep Expertise is Unlocking the Final Frontier of Wind Blade Inspection

As the global wind fleet ages, a critical and often unseen area of maintenance is gaining urgent relevance: internal blade inspection. To understand this new frontier, we spoke with Armando Costa, Executive Director of the Brazil-based inspection leader Arthwind.

He explains how the company's unique blend of practical technology, rigorous methodology, and deep-seated manufacturing expertise is helping operators across Latin America and beyond to detect damage earlier, mitigate catastrophic risks, and build smarter, more scalable O&M strategies.

From Aerospace to Wind Power: A Legacy of Expertise

Brazils position as a center of excellence in wind blade manufacturing didnt happen by accident. It was built on a strong foundation of knowledge transferred from the countrys established aerospace industry in the late 1990s. Pioneers like Bento Koike of TECSIS, who came from the aerospace sector, leveraged expertise in composite materials and aerodynamics to produce high-precision blades for global leaders like Enercon. This legacy created a highly skilled workforce that is now present in top blade service and manufacturing companies worldwide.

This deep-rooted expertise, combined with the rapid deployment of large-scale onshore turbines (gt;4MW) in Brazil, created an environment where advanced inspection technologies were not just welcomed, but necessary. Its no surprise that the use of rovers in internal inspections was quickly accepted, says Costa. Last year alone, Arthwind conducted internal inspection in over 35% of the installed fleet in Brazil, and this year that number will exceed 40%.

The Unique Challenge of Looking Inside

Internal blade inspection is far more complex than its external counterpart. The challenges are numerous:

• Access and Logistics: It requires uptower access and data collection in confined, unpredictable spaces.
• Image Quality: Factors like dirt, variable lighting, and surface inconsistencies make internal imagery difficult to capture and interpret.
• Product Knowledge is Crucial: Modern blades have structural nuances that require deep manufacturing knowledge. Internally, not everything that looks different is a defect, Costa notes. Manufacturing residues, material differences and discoloration can all appear without being problems. A lack of this understanding can lead to false positives or, worse, missing critical issues.

A Proactive Approach: Technology Guided by Expertise

Arthwind’s approach combines simple, robust technology with a team of professionals who have hands-on manufacturing backgrounds. In 2020, the company introduced the ArthBot, a rover designed for easy operation and maintenance in the field.

This technology is guided by a robust inspection protocol called the KIN methodology. This three-year cycle involves:

• Year 1: Mapping every deviation inside the blade, whether its a confirmed defect or not.
• Years 2 & 3: Monitoring these findings to see what has Kept the same, what has Increased in severity, or what is New.

We notice that small deviations, often overlooked during inspections, become a risk when they begin to progress, Costa explains. Mapping wrinkles, waves, or core gaps ensures early-stage detection and significantly lowers repair costs.

The Call for an Industry-Wide Shift

With turbines now operating blades over 70, 80, or even 100 meters long, relying on outdated Oamp;M protocols is no longer viable. Costa argues that the industry has scaled up, but its inspection strategies havent kept pace.

Internal blade inspections must be embedded in the operational model from day one... and should no longer be treated as exceptions, he urges. Yet, an estimated 80% of the industry remains reactive. The good news is that OEMs are becoming more proactive, especially for turbines over 4 MW, with many establishing annualized inspection protocols.

Democratizing Technology and Avoiding "Shiny Tool Syndrome"

Arthwind’s mission is to democratize inspection technology. In practice, this means:

• Making field technicians safer and more confident by using rovers instead of entering long, confined blades.
• Giving wind farm operators insight into previously unmapped risks.
• Creating clear, logical severity standards that translate complex imagery into actionable fleet risk levels.

However, Costa warns against shiny tool syndrome. The rush for low-cost gadgets can overlook the most critical component: the expertise behind the data analysis. Our rover is simply a collection tool, he states. The first barrier is knowing what truly constitutes a defect... it requires a firsthand understanding of blade manufacturing.

Looking ahead, Arthwind is focused on connecting the entire blade maintenance chain within its ArthNex ecosystem, using its platform to boost field efficiency, enhance quality control, and scale sustainable Oamp;M strategies.