— A P P L I C A T I O N
Wind Turbines
Wind turbines operate in some of the most lightning-exposed environments on earth. Astrostrike® is
embedded within blade laminates and structural components to protect assets, extend service life, and
ensure reliable energy production.
— T H E C H A L L E N G E
Lightning is the leading cause of wind turbine blade damage
Wind turbines operate in open, elevated environments where they are among the most exposed structures in any landscape. Composite blades are particularly vulnerable — a single lightning strike can cause surface erosion, resin burn-through, spar cracking, delamination, and loss of aerodynamic efficiency, resulting in unplanned downtime and costly repairs.
Astrostrike® expanded metal mesh is embedded within the blade laminate — typically near the leading edge — where it forms a continuous conductive network that captures lightning attachment, distributes energy laterally across the blade surface, and routes current safely into the internal down-conductor system and into ground.
— K E Y B E N E F I T S
Captures and routes lightning energy away from structural composite
Reduces risk of spar cracking, delamination, and resin burn-through
Supports longer blade service life and reduced maintenance intervals
Compliant with wind industry lightning protection requirements
Lightweight — minimal impact on blade aerodynamics and weight balance
Compatible with standard composite blade manufacturing processes
— A D V A N C E D B O N D I N G S O L U T I O N S
Structural bonding and lightning protection in one integrated system
Astroseal's expanded mesh film adhesives combine high-performance structural epoxy films with lightweight metal mesh to create bonding and core solutions that deliver structural integrity and lightning protection in a single material — simplifying the manufacturing process and reducing assembly steps.
These heat-activated systems are widely used in aerospace, wind energy, automotive, and sporting goods applications to bond metals, composites, and honeycomb structures. They enable high-strength sandwich panels with superior strength-to-weight ratios, improved gap filling, faster assembly, and reduced material waste compared to traditional bonding methods.
LC-E260-CU015 demonstrates excellent adhesion and toughness across cure cycles from 250°F (121°C) to 350°F (177°C), and is recommended for operating temperatures from -67°F (-55°C) to 300°F (149°C). Multiple weights and thicknesses are available.
PHYSICAL PROPERTIES
Adhesive Areal Weight: 0.030 ± 0.005 psf
Resin Content: 50%
Mesh Areal Weight: 0.015 ± 0.0025 psf
Major Pitch: 0.065 ± 0.0075 in
Minor Pitch: 0.041 ± 0.0075 in
Mesh (Major) Resistance: 0.035 max
Mesh (Minor) Resistance: 0.085 max
Tack: Medium
CURE PROPERTIES
Gel Time: 3–7 min @ 275°F (135°C)
Gel Time: <2 min @ 350°F (177°C)
Volatile Content: <1.5% @ 275°F (135°C)
Flow: 30 ± 10% @ 100 psi @ 275°F (135°C)
Where ASTROSTRIKE® is Applied
Nacelle Components
The nacelle houses the generator, gearbox, and power electronics — all sensitive to lightning-induced surge currents and electromagnetic interference. Composite nacelle enclosures incorporate Astroseal's expanded metal mesh to provide EMI shielding for these critical systems, preventing induced currents and radiated interference from degrading the performance or longevity of nacelle electronics and electrical systems.
Composite Blades
Rotor blades are the primary lightning attachment point on a wind turbine. As blade diameters grow — with modern offshore blades exceeding 100 meters — reliable, lightweight lightning protection embedded in the composite laminate becomes increasingly critical. Astrostrike® mesh is integrated near the leading edge during the manufacturing layup process, forming the primary conductive network that intercepts and safely routes strike energy to the down-conductor system. Its compatibility with standard composite manufacturing processes means no special tooling or process modifications are required.
Aerodynamic Fairings
Aerodynamic fairings — including trailing edge panels, vortex generator bases, and blade root fairings — are secondary composite structures that must be protected from both direct lightning attachment and induced currents propagating from primary strikes. Astrostrike® provides lightweight, thin-profile protection suitable for integration into these smaller, curved structures without compromising aerodynamic performance.
Structural Housings
Structural composite housings on wind turbines — including hub nose cones, spinner fairings, and transition pieces — require both lightning protection and structural reinforcement. Astrostrike® mesh provides the conductive path for lightning protection while simultaneously reinforcing the composite laminate, improving inter-ply bonding strength and resistance to the mechanical fatigue imposed by continuous rotation and wind loading.
Maintenance & Retrofit
For turbines already in service, Astrostrike® is available for maintenance and retrofit applications — including leading edge protection systems, repair patches for lightning-damaged blade areas, and retrofit shielding for nacelle electronics enclosures. Its bond-ready surface treatment ensures compatibility with field-applied adhesive systems, and its flexibility allows application to complex blade geometry without specialized tooling.