popularmechanics.co.za MAY / JUNE 2022 57
THE SOLUTION
What if the intrinsic shape of the blade
could change? Perhaps in the same way
that a bird’s wing changes shape during
different flight scenarios, giving lift when
needed but then morphing in shape to dial
back the forces as the wind gets stronger.
South African start-up Brayfoil
Technologies has patented a method of
changing the shape of a wing in operation,
while linking that shape change to the pitch
of the wing. A technological breakthrough
sought after by some of the world’s largest
innovation and aerospace agencies, but
never quite perfected to the point of being
viable, Brayfoil’s intellectual property offers
a groundbreaking new way of thinking
about how wings operate, which replaces
complex shape-change systems (such as
flaps and ailerons on aircraft wings) with
a simple shape-changing shell.
Coupled with a unique approach to
pitch angle, with pitch being driven by the
physical forces created by the shape, this
makes the blade’s shape adapt faster to
changing winds, much in the same way
a bird’s wing changes both the angle and
the shape of its wing as it comes in to land.
What this translates to in a wind-
turbine application is a reduction in
the twist and camber in the blades, an
astonishing reduction in storm loadings of
up to 90 per cent, a decrease in operational
loads of up to 24 per cent, and an increase
in performance of up to 60 per cent during
unstable wind scenarios.
The net effect here is lower forces on
the entire structure, which can be used in a
number of ways. Wind turbines can either
be made more reliable, or the blades can
be made longer. For the same structural
strength at the base, the introduction of
this tech is projected to allow a 13 per cent
increase in blade length, which relates to
a significant 25 per cent annual energy
production increase. Technology such as
this would change the economics of wind
power even further, resulting in a 20 per
cent decrease in the lifetime cost of energy,
particularly valuable in offshore floating
wind-turbine applications which are
currently in need of enabling technologies
in order to bring costs down.
Another important aspect of this is the
advances in recyclability. Recyclable resins
and composites are becoming the industry
standard, and these are advances with
which Brayfoil’s technology is well aligned,
while not changing the manufacturing
process significantly. With cost estimates
suggesting that the tech could be capex and
opex neutral, this will be a major focus of
future development.WHERE IT
ALL STARTED
During Matthew’s school years,
he and his father Robert Bray
worked together on many of his
science projects. These included
exhibiting in the Taiwan and
Namibian international science
fairs, as well as building an electric
car together when Matt was 14.
Matt and Robert’s shared
passion for innovation, coupled
with Robert’s illustrious career as
a prolific architect in South Africa
and Matthew’s background in
finance at Goldman Sachs and
BASF, made for the perfect foun-
dation for Brayfoil’s revolutionary
technology. Brayfoil has grown
from a passion project in Robert’s
garage into a groundbreaking
emerging technology that has
gained international recognition
from some of CleanTech’s most
respected institutions. It’s all a
remarkable legacy left behind
by Robert Bray, who sadly
succumbed to complications
from COVID-19 in 2020.23Matthew Bray, Co-founder and
CEO of Brayfoil Technologies