Inside the Wind Turbine Project: Innovation by Leo L. ’30

Leonardo (Leo) L. ’30 was immediately hooked when he first heard about the class wind turbine project. The challenge: design, build, and test a working turbine, improving it step-by-step just like real-world engineers. While the assignment required students to study complex physics concepts, for Leo, the most exciting part was uncovering how air moves and the invisible forces acting on the spinning blades.

“He independently researched lift and drag principles and began designing blade prototypes in CAD, demonstrating the self-directed curiosity that defines strong engineering students,” explained Mrs. Macy Hammond '16, Middle School Science teacher.

Instead of common classroom materials, such as cardboard or balsa wood, Leo prioritized precision. He taught himself computer-aided design (CAD) software to create custom blades and chose to 3D print them, allowing him to control every detail of their shape. “Leo took the initiative to design and 3D print his own blade prototypes, utilizing CAD software to translate theoretical principles into physical designs,” Mrs. Hammond said.

Bringing those designs to life came with challenges. Leo used a mix of carbon fiber and PLA, an environmentally friendly plastic, and worked to reduce weight without sacrificing strength. He experimented with internal air pockets and designed openings in the blades, carefully aligning the print direction to ensure smooth airflow.

“Leo exemplifies engineering thinking, he approaches problems analytically, maintains a solution-oriented perspective, and seeks out opportunities to refine his ideas during non-class time,” Mrs. Hammond shared. She added that he “truly thinks like an engineer, visualizing problems from multiple angles and focusing on solutions rather than obstacles.”

The class project required teams to test multiple turbine blade designs in varying wind conditions to measure energy output. Leo printed a wide range of blade variations, carefully tracking results to determine what performed best. “During testing trials, Leo’s genuine enthusiasm for the engineering process was unmistakable,” Mrs. Hammond noted. “The joy on his face as he observed his designs in action reflected a student deeply engaged in problem-solving and discovery.”

On the final day of competition, Leo and his teammates took a risk, testing a brand-new, unproven set of blades. When the blades broke under pressure, the team quickly pivoted, repairing what they could and switching to a reliable backup design. Thanks to what Mrs. Hammond described as his “technical skills and willingness to iterate,” the team secured first place, winning by just 100 milliwatts.

Reflecting on the experience, Leo offered simple advice for future students: “Never give up, even when you think your design is finished.”