Abstract: Under the driving force of China’s dual-carbon goals, the wind power industry has rapidly developed, with large-scale blades (exceeding 100 meters) becoming a central trend. However,industrialization faces challenges from composite material performance to limited innovation in process synergy. This paper systematically examines the application status and technical challenges of key material systems in wind turbine blades, including reinforcing fibers, matrix resins, core materials, and structural adhesives. Key findings highlight that increasing domestic production of carbon fiber advances lightweight development; hydrolysis-resistant modifications in polyurethane resins enable cost reduction; PET foams speed up the replacement of traditional core materials; and structural adhesives achieve compatibility with 100-meter blades through toughness and rheological improvements. Additionally, this study suggests directions for multiscale simulation optimization and smart manufacturing by comparing the effectiveness of vacuum infusion, pultrusion, and prepreg processes. To manage decommissioned blades, the paper assesses the industrial potential of mechanical, pyrolysis, and chemical recycling methods and stresses the importance of closed-loop recycling systems for sustainable growth. By analyzing materials, processes, and recycling across the entire chain, this research offers comprehensive solutions for ultra-long blade R&D, helping the wind power sector surpass cost-performance limits and speed up the shift to green energy infrastructure.

Key words: wind turbine blade; composites molding; carbon fiber; recycling