Experimental Study of Comprehensive Performance Analysis Regarding the Dynamical/Mechanical Aspects of 3D-Printed UAV Propellers and Sound Footprint

The present study evaluates the viability of fabricating unmanned aerial vehicle (UAV) propellers using fused filament fabrication (FFF), with an emphasis on low-cost, desktop-scale production. The study's backdrop is the recent adoption of UAVs and advancements in additive manufacturing. While the scope targets accessibility for individual and small-scale users, the results have broader implications for scalable UAV propulsion systems. The research was conducted within an experimental UAV development framework aimed at optimizing propeller performance through strategic material selection, geometrical design optimization, and additive manufacturing processes. Six propeller variants were manufactured using widely available thermoplastic polymers, including polyethylene terephthalate glycol-modified (PETG) and thermoplastic polyurethane (TPU), as well as photopolymer-based propellers fabricated using vat photopolymerization, also known as digital light processing (DLP). Mechanical and aerodynamic characterizations were performed to assess the structural integrity, flexibility, and performance of each material under dynamic conditions. Two blade configurations, a toroidal propeller with anticipated aerodynamic advantages and a conventional tri-blade propeller (Gemfan 51466-3)-were comparatively analyzed. The primary contribution of this work is the systematic evaluation of performance metrics such as thrust generation, acoustic signature, mechanical strength, and thermal stress imposed on the electrical motor, thereby establishing a benchmark for polymer-based propeller fabrication via additive manufacturing. The findings underscore the potential of polymeric materials and layer-based manufacturing techniques in advancing the design and production of UAV propulsion components.