Drone/Plane Propellers– generative design, any size

thingiverse

In 3D printing an RC Stearman model, I needed an 11x5.5 prop instead of paying $3 for one, so I spent thousands of person-hours using high-expertise design skills to build this amazing propeller. It's a procedurally generated propeller design that is variable-enabled, allowing you to enter your dimensions and get a custom prop or customize it to your heart's content. Don't like my vortex generators? Remove them or change them as you see fit! I'd love to build up this document with different sizes that people can download easily - if you want a size or variation not listed here, just let me know and I'll get you the STL file and upload it here. Leave a comment or send me a telegram at [t.me/coolwheel](https://t.me/coolwheel). ## Printing To print this propeller, you need to use supports and then sand it down. I recommend using high-temperature PLA+ to print with because it anneals when oven-heated and becomes even stronger. Here's my process: * Print upside-down with ~55-degree overhang supports. This makes the thin trailing edge come out great. * Use 3 wall perimeters with super-thin 0.1mm layers and a high infill of 'lines' or 'grid' to keep it symmetric and balanced. * Optional annealing: + After printing, leave the supports attached + Bake in oven for ~10-15 minutes at 220F + Carefully remove supports - they're stronger now, so go slow! * Sand sand sand! I: + Start by using a combination of a dremel sander and 80-120 grit to get all the layer lines out on the top and bottom surfaces (bottom is more important) + Then I wet sand with ~200 grit, ~300 grit, ~400 grit, and ~800 grit That's it! My 11x5.5 prop takes ~5h of printing, 15m to bake, and 1h to sand/finish. ## Source / Design File Designed in Onshape, the next-generation solidworks in the web (and mobile apps), this design is available for free download. Here's the public document: [b.link/propGen](https://b.link/propGen). Anyone can fork and extend the design for free! Also, here's the page to get a free account: [onshape.com/en/products/free](https://www.onshape.com/en/products/free) - they keep it hidden from their main site. ### Post Your 'Make'! Show me what you've made! I want to see!