Hydroelectric energy systems and methods of manufacturing the same

A method of manufacturing a stationary ring structure for a hydroelectric energy system, the method comprising:

• forming a foundation for the stationary ring structure, the foundation having a circular shape with a U-shaped cross-section, wherein the U-shaped cross-section comprises a base and first and second side walls extending substantially perpendicular to the base, the foundation having at least one slot configured to receive a plurality of electricity-generating elements;
• affixing the plurality of electricity-generating elements within the at least one slot of the foundation;
• overlaying the foundation with a mold, such that the mold adjoins the first and second side walls and the foundation and mold together define a sealed internal cavity;
• and
• filling the internal cavity with a core material, the core material being configured to harden to form a backing of the stationary ring structure, the backing being configured to be in compression during operation of the hydroelectric energy system.

A method of manufacturing a hydroelectric energy system comprising a stationary ring structure and a rotating ring structure, the method comprising:

• positioning a stationary ring mold over an inner circumferential surface of a stationary ring foundation to form an internal cavity between the stationary ring mold and the stationary ring foundation;
• affixing a bearing material to an outer circumferential surface of the stationary ring foundation;
• inserting a thin layer of an abradable material over the bearing material, wherein, during operation of the hydroelectric energy system, the abradable material is configured to wear away to form a bearing gap between the stationary ring structure and the rotating ring structure;
• filling the internal cavity formed between the stationary ring mold and the stationary ring foundation with a core material, the core material being configured to harden to form a backing of the stationary ring structure;
• and
• attaching a blade support ring to a rotating ring foundation to form the rotating ring structure, the blade support ring comprising one or more blades, each blade extending both radially inwardly of the blade support ring and radially outwardly of the blade support ring.