Assessing Non-Planar Slicing and Carbon Fibre Filament Additives as Steps Towards 3D-Printed Drone Propellers

Propeller design dramatically influences the performance of a drone and its ability to complete a mission. Operators in the field cannot carry the best propeller for any possible conditions, but with the advent of capable end-user 3D printers, may be able to manufacture them. This research assesses how non-planar model slicing and short-chopped carbon-fibre additives affect the mechanical performance of printed parts and viability of printed propellers. Creep testing simulating propeller thrust loading found coupons varied greatly in time to failure, although benefits of carbon-fibre additives were detected. Drop tests assessed impact behaviour, finding no link between material or slicing style and performance for a realistic propeller geometry. Simpler geometry resulted in both factors affecting performance, indicating possible benefits when applied in suitable situations. Results can be used to make informed selections of material and slicing type, also guiding future attempts at 3D-printing propellers.