Popișter Florin
Department of Design Engineering and Robotics, Faculty of Industrial Engineering, Robotics and Production Management, Technical University of Cluj-Napoca, B-dul Muncii 103-105, 400641 Cluj-Napoca, Romania.
Polymers (Basel). 2025 May 25;17(11):1466. doi: 10.3390/polym17111466.
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.
本研究评估了使用熔融长丝制造（FFF）技术制造无人机（UAV）螺旋桨的可行性，重点在于低成本的桌面级生产。该研究的背景是无人机的近期应用以及增材制造技术的进步。虽然研究范围针对个人和小规模用户的可及性，但研究结果对可扩展的无人机推进系统具有更广泛的意义。该研究是在一个实验性无人机开发框架内进行的，旨在通过战略性材料选择、几何设计优化和增材制造工艺来优化螺旋桨性能。使用广泛可得的热塑性聚合物制造了六种螺旋桨变体，包括聚对苯二甲酸乙二醇酯改性（PETG）和热塑性聚氨酯（TPU），以及使用光聚合反应制造的基于光聚合物的螺旋桨，也称为数字光处理（DLP）。进行了机械和空气动力学表征，以评估每种材料在动态条件下的结构完整性、柔韧性和性能。对两种叶片配置进行了比较分析，一种是具有预期空气动力学优势的环形螺旋桨，另一种是传统的三叶螺旋桨（Gemfan 51466 - 3）。这项工作的主要贡献在于对诸如推力产生、声学特征、机械强度以及施加在电动机上的热应力等性能指标进行了系统评估，从而为通过增材制造制造基于聚合物的螺旋桨建立了一个基准。研究结果强调了聚合物材料和基于层的制造技术在推进无人机推进部件设计和生产方面的潜力。
