Skywalker project revolutionises the manufacturing of tall wind turbine towers through high-precision automated welding

Nabrawind Technologies, in collaboration with KishGroup, has successfully completed the Skywalker project, an R&D initiative aimed at transforming the manufacturing of critical structural components for the next generation of large-hub-height wind turbines.

As the wind sector strives to reach hub heights exceeding 140 metres in order to harness stronger and more consistent winds, the logistical and assembly challenges associated with conventional tubular towers become increasingly insurmountable. Nabrawind has addressed this challenge with its Nabralift technology, a self-erecting tower that eliminates the need for heavy-lift cranes.

Within this context — where maximising tower strength becomes a critical requirement, particularly at structural nodes — Skywalker was conceived. The project develops a welded joint that combines high mechanical performance with industrial repeatability, applicable to complex geometries and thick sections without compromising productivity.

Pushing beyond the limits of traditional manufacturing

The welded joints at structural nodes directly determine fatigue life, in-service reliability, and overall manufacturing cost.

Conventional arc welding processes are highly mature and widely available; however, they require multiple passes, involve high heat input, and depend significantly on manual adjustment. These factors increase weld variability, raise the risk of defects, and extend manufacturing times, particularly in difficult-to-access configurations.

The Skywalker project, by contrast, develops and validates a hybrid welding method and advances process automation through robotics and advanced sensing technologies.

Results: high power hybrid welding

The main milestone achieved by Skywalker has been the development of a welding solution with significant penetration capability, incorporating adaptive and control functionalities to ensure reliable operation on complex geometries.

During final testing, consistent evidence was obtained demonstrating process stability, quality control, and the absence of critical defects, establishing a clear technical roadmap for industrial scale-up.

Industrial protection and global deployment

The technical robustness of the results has led to the granting of a new patent entitled “Method for Manufacturing Columns for Wind Turbine Towers”, published on 18 December 2025.

The patent protects an innovative system in which components (tubes, diagonals and flanges) are positioned using dedicated tooling that guarantees the precision required for automated welding.

Impact on the wind sector

The success of Skywalker not only reinforces Nabrawind’s innovative DNA but also delivers a tangible solution to reduce manufacturing time, costs, and initial investment (CAPEX) in large wind farms.

This advancement positions the company at the forefront of industrial wind-structure manufacturing, enabling the deployment of wind turbines at unprecedented heights and directly contributing to the global competitiveness of onshore wind energy.

• Innovation: New automated hybrid welding method for thick sections.
• Efficiency: Reduced welding time.
• Quality: Structural light-weighting.
• Intellectual Property: New patent published in December 2025 with international projection.
• Collaboration: Project developed by Nabrawind and KishGroup.

This entity has received funding from the Government of Navarra, co-financed at 40% by the European Regional Development Fund (ERDF) through the Navarra ERDF Operational Programme 2021–2027.