March 2009

FlexSys Wind Energy, located in Ann Arbor, Michigan, was founded in 2008 as part of a diversification strategy of FlexSys Inc., a successful engineering design firm with a worldwide reputation in the field of bio-inspired engineering design and shape morphing structures.  University of Michigan professor Sridhar Kota founded FlexSys Inc. in 2000. Since its inception, FlexSys has received approximately $6 million in Department of Defense grants for designing, building and testing shape adaptive wings or airfoils.  An additional $7 million Air Force contract was recently awarded to FlexSys to construct adaptive replacements for commercial aircraft wing flaps.  Essentially, this 'morphing' system comprised of a novel composite structure, replaces conventional aircraft control surfaces and enables the wing to flex up or down like a bird's wing.  Despite the systems flexibility, it can withstand the tremendous forces associated with aircraft flight.         

This technology holds enormous promise, not only for flight applications but for other industries such as wind energy.  In fact, it is the knowledge obtained from their Defense Department funded work on wing development that is directly attributable to positioning FlexSys Wind Energy ahead of competitors in the wind energy industry.  Rich Vander Veen, FlexSys Vice-President for Business Development for Wind Energy, who is also a successful wind farm developer says, "I am eager to see the benefits of the FlexSys Adaptive Edge system realized in large scale wind farms."

Bob Gavin, President and CEO of FlexSys Wind Energy states, "The technology for constructing these seamless, flexing trailing edge wing flaps is significantly advancing the next generation rotor blade technology that FlexSys Wind Energy has developed for wind turbine blades.  Our technology specifically addresses the two principal limitations in the wind energy industry relating to the cost of energy produced – energy capture and system fatigue."  Larger wind turbine blades capture more energy but fatigue stresses increase exponentially with blade length.  Large wind turbines must operate under very turbulent and unpredictable environmental conditions.  Due to these factors, the loads on the blades vary over intervals of time much shorter than today's variable pitch blade rotors can respond. The goal of FlexSys Wind Energy is to capture more energy in low winds with longer blades, while controlling loads in high winds. 

According to Greg Ervin, FlexSys Wind Energy Operations Manager, "The key characteristic of our Adaptive Edge system enables turbine blades, for the first time, to respond to incoming wind through continuous sense-and-control.  Our patented technology has been extensively analyzed by Sandia National Laboratories, operated by Sandia Corporation for the U.S. Department of Energy.  In short, our technology allows blades to respond to varying wind speeds by changing the aerodynamics of the blade almost instantaneously".  Erven further explains, "By adapting blade shape to varying wind conditions, the FlexSys Adaptive Edge system offers a 15% increase in energy capture and a significant reduction in fatigue damage to the blade, thereby reducing manufacturing costs, operating costs and insurance costs." 

The Sandia National Laboratories experts have, in fact, demonstrated through sophisticated aerodynamic simulations, that the FlexSys Adaptive Edge can reduce turbine blade fatigue damage by 75%.  This kind of damage reduction means that with this technology either the turbine or tower for a given size rotor can be built with less material, maintaining the same energy capture; or a larger rotor can be used with the existing tower and drive train, resulting in an increase in energy capture.  "Either option will lead to reductions in the cost of energy," relates Gavin.  Jose Zayas, manager of Sandia Labs Wind Technology program states, "As a national lab and leader in wind turbine blade design we are well aware of other load control technologies that are being considered in the wind energy community.  In our opinion, the patented FlexSys technology is one of the most promising technologies being considered.  While other organizations are rushing to develop similar technology, FlexSys has already flight tested and fatigue tested the metallic rendition of its version.  As a result, FlexSys appears to be much closer to commercial application than the other organizations".

FlexSys Wind Energy has been aggressive in seeking out resources that can help the business grow.  Through Ann Arbor SPARK, the area business development organization, the company has connected with the Michigan Economic Development Corporation and the Michigan Small Business Technology Development Center.  In 2008, Kayo Ramirez, business technology consultant for the SBTDC began working with FlexSys.  "Kayo has had such a positive impact on our company.  He contributed significant assistance in the development of our business plan, continues to be a sounding board and resource and bends over backwards to help us move forward," relates Gavin.  "The technology developed by FlexSys Wind Energy can dramatically alter the way wind energy is captured and significantly reduce the costs of producing wind energy.  The technology is tremendous", states Ramirez.

Bob Gavin acknowledges, "FlexSys Wind Energy has a key challenge ahead; we need to prove our technology to the marketplace by building and testing a utility scale prototype.  We are actively seeking funding partners to meet these challenges." Venture Capital firms have exhibited keen interest in what FlexSys has developed but the company's principals are concerned that as often happens with venture capital financing, the company must move where the money is and FlexSys wants to remain in Michigan.  "We want to stay in Michigan, manufacture FlexSys components in this state and ship them around the world.  We see FlexSys as a perfect representation of what Michigan needs to do – take a traditional manufacturing base and transform that base into producing a higher value added product that produces good jobs and green technology," emphasizes Gavin.

Contact the SBTDC.