propeller

114 Articles

A 3D-printed propeller is shown mounted on a motor on a triangular test stand. Each corner has a load cell, and wires run from it to the right.

Building A Swashplate-less Helicoper Rotor

October 25, 2026 by 5 Comments

A helicopter blade uses a swash plate and a set of linkages to change the angle of the blades. Not only does it vary the collective pitch to increase or decrease thrust, but it varies each blade’s pitch throughout each rotation, letting it produce more lift on one side of the rotor. This presented a problem to [worked in theory] — he’s building an RC helicopter from scratch, and this mechanism added both complexity and weight. Instead, he started looking for a way to get around the problem.

There were two options to eliminate the linkages: a linkage-less swashplate design used in Black Hornet drones, and an under-actuated design using angled hinges to control the blade angle. [worked in theory] started with the Black Hornet design, which has the end of each blade run along the swashplate on wheels, while a central spring presses them down. Friction in the hinge and wheels proved too high, and it stopped responding at higher speeds. A second, lower-friction design seemed promising, but it still required actuators, and thus weight, to control the swashplate. [worked in theory] therefore moved on to the under-actuated approach. In this design, the blades are mounted on angled hinges — by varying the motor’s speed throughout each rotation, inertia causes the blades to swing backwards or forwards, changing their pitch.

[worked in theory] tested two such rotor designs: one with one hinge per rotor, and one with one hinge for both rotors. The design using a single hinge seemed less sensitive to friction, was more responsive in testing, and had a more linear control response, so he used that. To actually make the blades, [worked in theory] 3D printed them as flat blanks, then thermoformed them using printed molds. During testing, the blades needed weights added to pull them back toward the standard angle under constant rotation; fortunately, though, this had the side effect of damping out unwanted vibrations.

There’s still a long way to go before the helicopter’s finished, but this is quite an impressive start. This is the second under-actuated propeller we’ve seen recently, both inspired by [Tom Stanton]’s original design.

Continue reading “Building A Swashplate-less Helicoper Rotor” →

The Weird Propeller That Offers Improved Agility On The Water

February 6, 2026 by 49 Comments

When it comes to seaborne propulsion, one simple layout has largely dominated over all others. You pair some kind of engine with some kind of basic propeller at the back of the ship, and then you throw on a rudder to handle the steering. This lets you push the ship forward, left, and right, and stopping is just a matter of turning the engine off and waiting… or reversing thrust if you’re really eager to slow down.

This basic system works for a grand majority of vessels out on the water. However, there is a more advanced design that offers not only forward propulsion, but also steering, all in the one package. It may look strange, but the Voith Schneider propeller offers some interesting benefits to watercraft looking for an edge in maneuverability.

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Brass Propeller Gets Impressive Hand Trimming

September 22, 2024 by 4 Comments

Whether you’re a landlubber or an old salt, you’ve got to appreciate the effort that [The Aussie boat guy] puts into cutting an old brass propeller down into a far smaller and sleeker specimen. Especially since he does the entire thing with hand tools, a couple different calipers, and that most valuable of natural resources: experience.

The whole process was made somewhat easier by the fact that [The Aussie boat guy] had a model to work from — his friend had a small propeller that was already known to perform well, it was just a matter of cutting the larger prop down to match its dimensions. Using what appears to be pieces of leather (presumably for its flexibility), a template was made to accurately map out the front face of the blade.

As Bob Ross would say — “Here comes your bravery test”

By measuring out from the hub of the prop with his calipers, [The Aussie boat guy] was able to make sure the template was properly positioned before scribing its shape into the larger prop. An angle grinder was used to cut the shape out of each blade, followed by a smoothing off with a flap wheel.

But there was still a problem — the blades were the right shape, but they were far too thick. So he took the angle grinder to the back of each one to start removing material, using another set of calipers to occasionally spot-check them to make sure they were thinning out at roughly the same rate.

This thinning out process continued until the prop was brought into balance. How do you check that, you might be wondering? Well, if you’re a madman like [The Aussie boat guy], you chuck the thing into a power drill and spin er’ up to see how badly it shakes. But this only gives you a rough idea, so he has to move over to a somewhat more scientific apparatus that uses a set of parallel bars to help determine which blade is heavier than its peers.

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Sailing (Directly) Into The Wind

February 6, 2024 by 22 Comments

Humans have been sailing various seas and oceans for thousands of years, and using boats for potentially even longer than that. But as a species we wouldn’t have made it very far if it was only possible to sail in the same direction the wind is blowing. There are a number of methods for sailing upwind, but generally only up to a certain angle. [rctestflight] wondered if there was some way of sailing straight upwind instead and built this rotary sail craft to test the idea.

Normally a boat sailing upwind will sail approximately 45° into it, then “tack” 90° across the wind until they’re at another 45° angle from the wind, this time facing the opposite direction. This back-and-forth nature is not the most efficient path, so this vessel uses a few propellers to bypass the traditional sail. The first iteration, built on a sleek catamaran hull, uses a large propeller to catch the wind’s energy, then transfers it mechanically through a set of shafts to an underwater prop.

It took a few tries to get the size and pitch of both propellers narrowed down to where the boat would move forward into the wind, but move it does. A second major iteration of the build uses a single shaft with no gears, with the trade-off that neither propeller is facing an ideal direction, but this has the added benefit of the boat naturally pointing itself upwind.

While none of the designs are speed demons, the concept is sound enough. It’s just that, in most cases, performing multiple tacks to get upwind is acceptable compared to the extreme efficiency losses and drag from propeller-driven sailing crafts like these. A more effective way of propelling a boat upwind, at least using modern technology, might be to trade sails for solar panels.

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A pinwheel sits in an aquarium to simulate an offshore wind turbine. Bubbles come up from the "seabed" to encircle it to demonstrate a bubble curtain with an image of a sound waveform overlaid with the video to show the sound confined to the area within the bubble curtain.

Keeping The Noise Down Under The Sea

May 23, 2023 by 13 Comments

Since sound is the primary sense used by most ocean life, disruptions to the natural noise levels in the ocean from human activities can be particularly problematic for marine life. [DW Planet A] has a video describing some of the ways we can mitigate these disruptions to our friends under the sea.

Being noisy neighbors isn’t just a problem for whales but for everything down to the plankton at the base of the food web. Underwater construction like offshore wind installations get flak for being noisy, but technologies like bubble curtains can reduce noise output by up to 90% to the surrounding waters while still getting those nice low carbon energy benefits that prevent further ocean acidification and warming. Continue reading “Keeping The Noise Down Under The Sea” →

A black quadcopter sits on a grey surface. In place of traditional propellers are four figure eight propellers with sharp tips where the top and bottom of the eight would be.

Toroidal Propellers Make Drones Less Annoying

January 28, 2023 by 61 Comments

Despite being integral to aviation for more than a century, propellers have changed remarkably little since the Wright Brothers. A team at MIT’s Lincoln Lab has developed a new propeller shape that significantly reduces the noise associated with drones. [PDF via NewAtlas]

Inspired by some of the experiments with “ring wings” in the early 20th Century, researchers iterated on various toroidal propeller geometries until arriving at one that significantly reduces the sound produced by the rotors, particularly in the range of human hearing. The team suspects the reduction in noise is due to vortices being distributed over the whole propeller instead of just the tips.

Experiments show the drones can get twice as close before becoming a nuisance for human ears which should be great news for anyone hoping to launch Skynet commercial drone deliveries. Since the rotors are easily fabricated via 3D printing they should be easy to adapt to a number of different drones.

If you want to explore some more interesting drones, checkout this one that can fly and swim or this one that only uses a single propeller.

Printed Propeller Blades Repair Indoor Flyer

December 9, 2022 by 5 Comments

Fair warning for readers with a weak stomach, the video below graphically depicts an innocent rubber band airplane being obliterated in mid-air by a smug high-tech RC helicopter. It’s a shocking display of airborne class warfare, but the story does have a happy ending, as [Concrete Dog] was able to repair his old school flyer with some very modern technology: a set of 3D printed propeller blades.

Now under normal circumstances, 3D printed propellers are a dicey prospect. To avoid being torn apart by the incredible rotational forces they will be subjected to, they generally need to be bulked up to the point that they become too heavy, and performance suffers. The stepped outer surface of the printed blade doesn’t help, either.

But in a lightweight aircraft powered by a rubber band, obviously things are a bit more relaxed. The thin blades [Concrete Dog] produced on his Prusa Mini appear to be just a layer or two thick, and were printed flat on the bed. He then attached them to the side of a jar using Kapton tape, and put them in the oven to anneal for about 10 minutes. This not only strengthened the printed blades, but put a permanent curve into them.

The results demonstrated at the end of the video are quite impressive. [Concrete Dog] says the new blades actually outperform the originals aluminum blades, so he’s has to trim the plane out again for the increased thrust. Hopefully the extra performance will help his spindly bird avoid future aerial altercations.

On the electrically powered side of things, folks have been trying to 3D print airplane and quadcopter propellers for almost as long as desktop 3D printers have been on the market. With modern materials and high-resolution printers the idea is more practical than ever, though it’s noted they don’t suffer crashes very well.

Continue reading “Printed Propeller Blades Repair Indoor Flyer” →