Our CFD software gives us an optimized blade geometry that is then modeled. With the model we test strength of the design using Finite Element Analysis (FEA). FEA shows the stress distribution along the blade during given load conditions. From this we change the airfoil geometry either to strengthen the blade or thin it out to lighten the propeller if already strong enough. This results in a strong propeller design that will not break if you hit a gate or mid air collide. Frequency analysis is also done using FEA to figure out the vibration modes of the propeller. Tweaks are then made with the blade and hub attachment to get the first vibration mode to an acceptable level. The blades are offset forward
on the hub slightly to act as a swept back wing. During heavy loads this will the blade to flex open shallowing out the angle of attack effectively increasing the stall range. This gives the propeller a more linear feel throughout its throttle curve.
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