New 3D printing technology is helping expand micro hydropower projects across the US by reducing manufacturing costs and speeding up turbines production.
Researchers are using additive manufacturing to build customized turbine components for small hydropower systems that operate in low-head waterways and unused dams.
The project is being led by Cadens in partnership with the US Department of Energy’s Oak Ridge National Laboratory.
Engineers developed specialized components that simplify construction and lower the cost of small-scale hydropower installations.
The effort focuses on thousands of untapped US sites capable of generating clean electricity for local communities, industries, and remote areas. Researchers say the technology can help unlock more hydropower capacity while supporting the growth of reliable renewable energy systems.
The US has around 90,000 dams, but less than 3 percent currently produce electricity. About 51,000 of those sites have the potential for micro hydropower generation. They represent nearly 29 gigawatts of untapped energy capacity nationwide.
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Small hydropower projects often struggle with high costs because every site requires different turbine dimensions and designs. Seasonal changes in water flow also make standard equipment difficult to use. These challenges have slowed development despite growing demand for reliable renewable energy sources.
Researchers focused on lowering the cost of custom manufacturing without sacrificing durability. Their work showed that additive manufacturing can reduce costs per kilowatt by up to 40 percent compared to traditional production methods. That reduction could make many previously uneconomical sites financially practical.
Customized Turbines Built With Additive Manufacturing
Cadens developed software called ‘Turbine Builder’ to design hydropower components for different locations.
However, manufacturing those customized parts at low cost remained a major problem. Oak Ridge National Laboratory helped solve this by using large-scale 3D printing systems to produce key turbine parts quickly and efficiently.
The system used a large PVC pipe as the main water channel. Engineers then added specialized 3D-printed components that matched the pipe’s dimensions. This approach balanced standard parts with customized pieces, helping lower production expenses.
One important component was the draft tube, which improves turbine efficiency by directing water flow. Researchers printed the draft tube in two sections from a carbon-fiber-reinforced ABS polymer. After sealing the two halves together, the finished structure weighed about 688 pounds and was strong enough for long-term operation.
The runner housing, which surrounds the turbine blades, required greater precision. Instead of directly printing the housing, engineers printed a mold and used fiberglass casting to create the final part. CNC machining and protective spray coatings improved accuracy and helped protect the system from water exposure.
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The project also used Big-Area Additive Manufacturing technology to produce other components. These included pipe supports, wall thimbles, intake adapters, end cap flanges, and turbine runner systems. Large-scale printing enabled faster assembly of parts that would otherwise require expensive custom fabrication.
Micro Hydropower Gains Long-Term Industry Support
The prototype system has operated continuously at Cadens’ Wisconsin facility for more than six years. Researchers collected operational data during that time to improve turbine performance and energy conversion efficiency. The long testing period also helped validate the reliability of 3D-printed components in real operating conditions.
The 30-foot-long testing platform has become a research center for additional hydropower studies. Engineers now use it for material testing, simulation improvements, and energy storage experiments. The project also supports research into debris handling and biofouling resistance, which occurs when organisms accumulate on underwater equipment.
Micro hydropower systems produce far less electricity than large hydroelectric dams, but they can serve remote communities, farms, factories, and local power grids.
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Unlike solar and wind power, hydropower can generate electricity continuously when water flow remains stable. This makes it useful for improving grid reliability and supporting energy independence.
The success of the 3D-printed Fixed-Kaplan S-turbine shows how advanced manufacturing can reshape renewable energy infrastructure. Lower production costs and faster customization could help unlock thousands of unused hydropower locations across the US.
With companies continuing to improve designs and scale production, micro hydropower is expected to become a larger part of the country’s clean energy mix.
