Parametric model of fully printable propeller blade for RC airplane.

Now you can create propeller of any diameter with any pitch and any blades count, special for your airplane or may be drone (not tested).

In fact, i have stopped to buy propellers at all, now all my airplanes with takeoff weigh from 720g to 5kg flies only with printed propellers.

I have printed propellers from 6.5 inch to 16 inch in diameter, and this is not a limit.
Maximum RPM i have tested is about 16000. I dont have motors with higher RPM, because most of my airplanes has big motors and max RPM about 10000 with propeller.

After a long research i have fugured out how to print propellers vertically. In general case, after printing a blades, no post-processing or balancing required. This is the next level, much accurate than printed flat, and have the same strength.

In-flight video, P-51D 1.6m wingspan, 2.8kg takeoff weight, 4250-580kv, 6S, regular blade shape 15x13. Takeoff at 60% throttle :)

https://www.youtube.com/watch?v=Pnysn4RUmJM

There are two FreeCAD projects:

1. blade.FCStd - parametric blade
2. hub_58_3BL.FCStd - example of propeller hub

Now i have two blade shapes:

1. Master Airscrew S2 like
2. Regular (my own design)

First one produce more power and more consumption, second one have less current and thrust. I recommend to use regular shape for any aircraft, and MAS2 for high performance setup.

Please use PETG plastic for maximum strength, performance and ease of printing
Also i recomend to use airbrush nozzle for 3d printer. This really make sense for small propellers.
You may use ABS plastic for hub and propellers greater than 10 inch.
PLA not tested for blades, be carefull.

!!! WARNING !!! WARNING !!! WARNING !!!
Fast rotating propeller may cause serious injury in case of blow up!!!
Ensure that nobody stay in front or at the line of rotating propeller! Always stay behind!
Before flying, ensure that propeller has good strength. I can't guarantee that your print will be as strength as my because of difference in printers and threir settings.

Adjust your printer settings before testing with motor, test by hands first!!!
If your blades are weak - try to increase temperature.

Attention please:
If you are familar with propeller desing & CFD software, please help me with optimization of blade shape to get better performance.

PS
If you have any questions about 3d printed propellers, feel free to ask me :)

Updated: 05.11.2020

• FreeCAD project updated to be compatible with current version of Curves WB