I was curious how much load can this propeller handle. Since original propeller hub uses quite weak mounting design, I redesigned it to fit my needs.

Blades need to be fixed in place by thin CA glue. Put a drop of CA glue in the gap after the blades are inserted.

TODO: Complete stress test with measurements.

WARNING: It is NOT safe to use this propeller in uncontrolled environment. High RPM can (and probably will) cause structural damage leading to explosive decomposition. Fast moving fragments of destroyed propeller could cause serious injuries to people or animals. Proceed with caution.

Prusa

Prusa Mk2

Yes

No

0.2

15%

Rotate the blade by 90 degrees before slicing. It needs to be printed vertically.

There is only 0.1mm clearance between parts to achieve really tight fit. If you are having problems putting the propeller together, make sure you have calibrated all printer axes including extruder.

When slicing the model, set number of perimeters to 3 (minimum). Perimeters are supposed to handle all inertial and centrifugal forces.

I used original blade STL and recreated it using Rhinoceros 3D editor. Then I designed central cone and changed the way how blades are connected to it.
The cone is designed to fit the shaft of AX-4008Q BLDC motor.