Analysis of Thrust Performance and Noise Generation of UAM Composite Propellers Fabricated Using Composite-Based Additive Manufacturing

Urban air mobility (UAM) is an emerging transportation concept that uses lightweight, efficient aircraft for transporting goods and passengers and performing other logistical activities. One of the biggest challenges in developing UAM from a structural perspective is manufacturing strong and reliable propellers that are lightweight and durable. Traditional manufacturing methods for composite propellers are expensive, time-consuming, and difficult to scale. This study explores a new approach using Composite-Based Additive Manufacturing (CBAM) to produce high-performance propellers more efficiently. CBAM allows for the fabrication of strong, lightweight composite propellers using short manufacturing lead times. However, one challenge with this technique is that the propellers have a relatively rough surface, which can adversely affect airflow and performance. Two polymer surface coatings were evaluated to improve the smoothness of CBAM propellers. The microstructure and surface roughness were evaluated, and thrust force and noise levels of coated and uncoated composite propellers were measured and compared with commercially available comparable propellers. This research aims to show how CBAM could be a time-efficient and scalable solution for producing next-generation propellers for UAM applications.