I’ve spent a few years writing software to create props, based on about 12 years research and over 1 million CPU hours of CFD genetic-optimisation - I’m good with software, but no so good with making things that are bigger than my FFF printer…
Is anyone interested in collaborating on an “ideal prop” ? I’ll supply the design, your task is to make and test it.
Background: two different mates of mine made their own props: one used a chainsaw and a fence post (no joke - he’s a not-so-wealthy farmer) and the other cannibalised an industrial air-conditioner and used the nylon blades out of it. Both of those worked almost exactly as well as my stupidly-expensive “blah blah optimised” helix carbon prop… which lead me to the realisation that even the really expensive prop-sellers who claim to have great designs, are either wrong or lying.
My (free) software is a Fusion360 add-in (foils.pro) - but the released version does not include the optimised sections for air-screws (the new DB is 67 gigs - too big to ship as an update…).