Building Materials for the Vortex40 Vertical Wind Turbine

The Vortex40 vertical wind turbine can be built using a variety of materials. The basic version uses simple materials from a DIY store. The necessary individual components can also be found at a scrapyard or recycling centre.

Sustainability is another important consideration in the design of the vertical wind turbine. As many components as possible in the basic version are recyclable. Plastic is avoided wherever possible.

To provide an overview of the options, we distinguish between the following variants:

• BASIC: The building plan describes the BASIC version. It uses simple materials available from any DIY store. Only the magnets and enamelled copper wire for the stator are usually ordered from specialist online shops. In theory, these components can also be recovered from electronic waste.
  
• MOD: Simple changes to the choice of materials can considerably increase the output of the vertical wind turbine. Strong neodymium magnets, the magnet carrier plate and the ball-bearing-supported shaft are particularly important here.
  
• CUSTOM: The CUSTOM version grew out of suggestions from the community. It uses special materials that make the vertical wind turbine lighter, faster or more durable.

The CUSTOM version achieves the highest output, but the materials used also make it the most expensive and less sustainable version.

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Blades

Blade ribs

BASIC:
10mm pine plywood

MOD:
10mm beech plywood

CUSTOM:
8mm balsa wood (lightweight)
9mm film-faced plywood (strong)

Blade spars

BASIC:
10mm pine plywood

MOD:
10mm beech wood

CUSTOM:
10mm Aluminium

Blade surface

BASIC:
350g cardboard, surface coated with waterproof paint

MOD:
350g cardboard covered with glass fibre + resin

CUSTOM:
solid-profile cut polystyrene

Blade securing

For the six blade securing elements, you can use fishing line, galvanised perforated fixing strip or cut aluminium pieces.

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Rotor

BASIC:
10mm pine plywood
Alternatively covered with glass fibre + resin

MOD:
10mm beech plywood

CUSTOM:
12mm film-faced plywood (strong)

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Stator

Stator housing

BASIC:
10mm pine plywood

MOD:
10mm beech plywood

CUSTOM:
12mm film-faced plywood

Stator filling

BASIC:
epoxy resin

MOD:
epoxy resin

CUSTOM:
expanding construction foam or CNC machining to size

Stator-to-mast mounting

BASIC:
2.5-inch reducing socket

MOD:
2.5-inch brass reducing socket

CUSTOM:
40mm aluminium satellite-dish mounting tube, cut to length

Stator shaft and support

BASIC:
1/2-inch nipple, 40mm long, as shaft support
matching threaded brass bolt as shaft
brass nut and brass cap nut

MOD:
2 standard ball bearings as shaft supports
matching threaded brass bolt as shaft
brass nut and brass cap nut

CUSTOM:
2 high-performance cylindrical bearings
custom-made threaded brass shaft
brass nut and brass cap nut

Stator coils

BASIC:
enamelled copper wire 0,8mm

MOD:
enamelled copper wire 1mm

CUSTOM:
enamelled copper wire 0,8mm + 1,2-1,5mm

Stator magnets

BASIC:
rectangular ferrite magnets

MOD/CUSTOM:
rectangular neodymium magnets

Connection / stator voltage-doubler housing

BASIC:
brass screws

MOD:
IP64 junction box
Stator voltage doubler (in the building plan)

CUSTOM:
IP64 junction box milled from beech

Stator voltage doubler
Doubles the output voltage from 3V upwards. In the building plan included.

Stator connection
1.5mm IP64 rubber cable, 3 cores