Does anyone have ever try or see aluminium propeller on a paramotor? Would it be possible to make this on a CNC with the proper CAD? I’m working in a ski manufacturing company with multiple CNC and one is for aluminium. We use a lot of product such as carbon and fiberglass but the aluminium would be much cheaper and easier on the CNC to make.
Draw it up in cad and see what the mass is. It would be interesting to see. It has been done → These guys make general aviation props from aluminum. Aircraft | Sensenich Propellers
In general, the more robust the propeller is, the more damage that can occur if something goes wrong. I’ve broken nearly 10 props over my 22 year flying career and am glad each one was breakable. You really don’t want an aluminum prop, in addition, it would be much heavier than most newer props that are carbon fiber and will be slower to spool up.
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Thanks for the input! I understand the weight difference, I was just wondering if it was possible or already done.
The cost of new carbon prop in Canadian currency is around 450$ plus shipping for the cheapest 140 two blades, a real killer.
In aluminium it would be around 100$ so my wallet make me thoughtful about an effective alternative. 
I second this!
Having seen what a wooden propeller does when it hits somebody vs what a carbon propeller does, I will never switch back!
I imagine an aluminium propeller would work as well as a wooden prop but it will probably be even better at removing limbs.
For context:
Some wooden propellers have a metal core and they will cut your arm off.
Carbon props might remove fingers but there’s a good chance they will break before cutting your arm off.
Most of my broken props were wood, I made wooden props for many years and they do not contain any metal. They are also designed to break easily to prevent harm to pilot.
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Thanks good to know, maybe we make them differently in France or maybe the one I saw was outdated because the only wooden prop I’ve had the misfortune to witness self-destruct contained a nasty looking metal rod. I’ve updated my original comment.