The manufacturing of renewable energy components using cold forming

The Department for Business, Energy and Industrial Strategy* reports that manufacturing industry generates the highest carbon dioxide equivalent emissions in the UK. Hence, the industry requires immediate implementation of process changes and initiatives to decrease emissions and waste while promoting sustainability. Manufacturers who are exploring sustainable options now implement low carbon production methods to differentiate themselves from their competitors.

This blog explores the sustainability challenges in renewable energy component manufacturing and evaluates cold forming as an alternative technology.

* UK Greenhouse Gas Emissions, by Standard Industrial Classification

Renewable energy sector and sustainability

As renewable energy demand grows, a sustainable manufacturing approach is needed to support environmental targets. Manufacturing processes such as machining and hot forging consume excessive energy while producing waste materials and carbon emissions that contradict the principle of sustainable energy.  

Renewable energy firms now prioritise resource efficiency and cost-effectiveness in their operations. Facing global pressure to achieve net-zero emissions alongside increasing material expenses manufacturers need to adopt methods and technologies that minimise energy use and raw material consumption while prolonging product lifespan.

Cold forming stands out as a technology with major positive impact in the field of renewable energy. Cold forming removes the requirement for high heat conditions which results in stronger and more precise components that save costs in wind, solar and hydro energy systems.

What is cold forming? 

The cold forming technology plays a major role in advancing renewable energy solutions. Precision cold forming represents an uncomplicated sustainable engineering approach. Manufacturers use this technology to produce numerous components that meet extremely high-quality standards. In cold forming technology a powerful press forces copper billets into a die under significant pressure. The process occurs at high speed and ambient temperatures with significantly reduced waste production compared to conventional machining processes.

Manufacturing components through cold forming decreases waste metal production by up to 80% compared to CNC milling alone. Companies dedicated to sustainability while aiming to reduce unit costs can benefit from extensive advantages through material savings.

The benefits of cold forming for renewable energy

By adopting cold forming technology, renewable energy sectors will gain multiple advantages including:

• Stronger, more reliable components – extreme weather conditions require more dependable components that have increased strength.
• Lower production costs – cold forming decreases production expenses by minimising energy use and material wastage.
• Sustainability-driven manufacturing – supports the environmental objectives of renewable energy systems.
• Higher efficiency – leads to better performance and lessens maintenance expenses.

How cold forming supports renewable energy

The renewable energy industry benefits from cold forming because it creates high-performance parts that enhance both reliability and efficiency. Here’s how it’s used across different energy sources:

Wind Energy

• The reliability of turbines increases with the use of cold formed bolts, fasteners and shafts.
• Components that are both lightweight and strong minimise damage from regular use.
• Corrosion-resistant materials ensure longevity in harsh environments.

Solar Energy

• Precision-formed brackets and mounts improve solar panel stability.
• The total system weight reduces due to lightweight frames but keeps structural strength intact.
• Cold forming during mass production reduces expenses in solar hardware manufacturing.

Hydropower

• Cold formed turbine shafts alongside bearings and connectors increase efficiency in hydropower systems.
• Hydro systems benefit from extended lifespans when corrosion-resistant components are used.
• Critical water-powered systems experience fewer failures thanks to precise cold forming techniques.

Cold forming technology stands as clear evidence of engineering ingenuity. Multiple sectors such as automotive and aerospace have achieved substantial benefits by using the built-in strengths of cold forming technology.

Renewable energy sectors can also minimise their ecological footprint through cold forming while manufacturing stronger and more efficient components. The move to sustainable practices must ensure environmental responsibility throughout the entire supply chain which spans energy production and component manufacturing.

The renewable energy sector can improve infrastructure durability and dependability alongside its green future pledge by adopting these alternative sustainable approaches.

A legacy of innovation: Luvata Welshpool’s sustainable cold forming techniques

Through our latest innovation in cold forming, stainless steel, along with other metals such as titanium, can be cold formed without the use of hazardous chemical solutions. Luvata Welshpool’s research and development team created this unique shell to eliminate galling. Consequently, components and tooling are not damaged, which often manifests itself in the form of scores or surface imperfections, ensuring consistent quality throughout.

You can rely on Luvata Welshpool for your manufacturing needs and for helping you support sustainability initiatives using cold forming techniques – get in touch with us to discuss how we can work together to achieve your goals.