Propeller Design – Projects and Applications
MAGCAD develops high-performance propellers for UAV, VTOL and aerospace propulsion systems.
Our projects range from custom UAV propeller optimization to complete propulsion system development.
Flowcopter – Heavy-Lift UAV Propeller Development
For Flowcopter, MAGCAD designed and manufactured custom propellers for a heavy-lift UAV with a hybrid hydraulic propulsion system. Development of a high-efficiency propulsion system for a next-generation UAV platform. The project focused on aerodynamic optimization and lightweight composite propeller design.
Technical Highlights
Result
The final propeller solution delivered high thrust efficiency at low rotational speeds, stable operation across flight regimes, and reliable integration into Flowcopter’s heavy-lift platform.
Application: Heavy-lift UAV
Focus: Low-RPM high-torque propeller design
Result: High thrust efficiency and stable operation
StriekAir VTOL Propeller Development
Ultra-Light Folding Propeller for High-Altitude VTOL Operations
For the UAV manufacturer StriekAir, MAGCAD developed a custom folding propeller optimized for VTOL applications.
The objective was to create an extremely lightweight and highly efficient propeller system that could integrate seamlessly with the existing propulsion units while significantly improving thrust performance.
The result is a 24.5 × 9 inch folding propeller, specifically engineered for demanding vertical take-off applications and operations in higher altitude environments.
The Challenge
VTOL platforms operate under very demanding conditions:
Standard propeller solutions often fail to deliver the required combination of low mass, high thrust and mechanical reliability.
The goal of this project was therefore clear:
Develop a purpose-built propeller that maximizes thrust while minimizing structural weight.
Result
The final propeller system delivers:
– significantly increased thrust
– extremely low structural weight
– inertia reduction
– improved efficiency in VTOL flight
– enhanced performance in higher altitude environments
The optimized production process also enables scalable manufacturing for larger UAV platforms and future propulsion systems.
Manufacturing Innovation
During the development process, the manufacturing workflow was also optimized.
Key improvements included:
These improvements allowed not only better performance but also higher production consistency for future series manufacturing.
Wind Tunnel Propulsion Validation
MAGCAD performs advanced propulsion system validation in wind tunnel environments in close collaboration with Windguard.
These tests allow precise measurement and analysis of complete UAV propulsion systems under controlled and repeatable conditions.
Key capabilities
WINDGUARD and MAGCAD accompany customers throughout the entire propulsion validation process. From defining the test setup to analysing the measurement data, our engineers work closely with clients to ensure reliable and meaningful results. This collaborative testing approach allows UAV developers to gain detailed insight into propulsion system behaviour and identify optimization potential for demanding mission profiles.
The combination of controlled wind tunnel testing and engineering expertise allows MAGCAD to deliver highly reliable propulsion performance data.
Modular Center Hub Propeller Systems
MAGCAD develops advanced modular center hub propeller systems for UAV and VTOL propulsion applications.
Instead of conventional monolithic propellers, individually mounted blades are integrated into a precision-engineered hub. This modular architecture enables highly adaptable propulsion solutions, allowing propeller geometry and system characteristics to be optimized for specific aircraft platforms and mission profiles.
Key capabilities
This modular hub concept enables MAGCAD to deliver highly adaptable and mission-optimized propulsion systems, supporting UAV developers with flexible propeller solutions for demanding operational environments.
Precision-machined modular center hubs for folding UAV propeller systems
MAGCAD x Voliro
Symmetry Meets Control
For the Voliro inspection UAV, the propulsion challenge was anything but standard: develop an ultra-compact 8-inch tail propeller that delivers strong, stable thrust in both directions of rotation—while remaining lightweight and perfectly balanced for a high-precision aerial robotics platform.
MAGCAD solved this challenge with a fully symmetrical propeller architecture, purpose-built for bidirectional performance and reliability in demanding inspection environments.
Engineering Highlights
By combining aerodynamic symmetry, precision manufacturing, and strict performance validation, MAGCAD created a propulsion component that perfectly complements Voliro’s unique aerial robotics platform.
Because when a drone can move in every direction, its propulsion system must perform in every direction.
