The Ultimate Buyer's Guide for Purchasing Carbon-Fiber Drone Propellers

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Propellers are a critical component of any FPV drone, and understanding the basics is essential for getting started in the hobby. The right propellers can make your drone fly faster, smoother, and more efficiently, while the wrong ones can cause instability and poor performance. In this guide, I'll break down everything you need to know about FPV drone propellers and share my top recommendations.

If you want to learn more, please visit our website.

Propeller Recommendations

Propellers come in various designs and sizes, each tailored for specific flight styles and purposes. Factors like pitch, shape, and material significantly impact performance. After years of testing and experience, I've narrowed down some of the best propellers for different use cases.

Best 5' Props

Best 5' Props for Sub250

Best 7' Props

Best 3' Props for Freestyle

Best 3' Props for Cinewhoops

Best 3.5' Props for Freestyle

Best 3.5' Props for Cinewhoops

Best 2' Props for Cinewhoops

Best Tiny Whoop Props

For Tiny Whoop propeller recommendations, check out my recommendations here: https://oscarliang.com/best-tiny-whoop/#31mm-Propellers-for-65mm-Whoops

How Does a Propeller Work?

Propellers (or just 'props') generate thrust by spinning rapidly, pushing air downward. Each blade has an airfoil shape, creating a pressure difference: lower pressure above and higher pressure below. This difference generates lift, propelling the drone upward or forward.

The front edge of the blade is called leading edge, which cuts into the air first. It splits the airflow, directing some over the curved surface (generating low pressure) and some under the flatter side (higher pressure). The rear edge of the blade is called Trailing Edge, where the airflow recombines. The combined pressure difference across the blade surfaces generates lift.

Fun Fact: FPV drones can't fly in space because there's no air for the propellers to move.

Understanding Propeller Specifications

FPV drone propellers are typically defined by three main dimensions: size, pitch, and blade count. These are often written as a set of numbers, such as 5x4x3 or ×3.

Size (Diameter)

The first number, like the 5 in 5x4x3, represents the diameter of the propeller in inches. This is the diameter of the circular area the prop creates when spinning.

• Larger Props: Generate more thrust due to a larger surface area but require more powerful motors. In my experience, with the right FPV drone motor, larger propeller tend to be more efficient. They generate more lift therefore can carry more payload,
• Smaller Props: Produce less thrust but are easier on the motor, changing RPM is faster therefore the drone can be more responsive and nimble.

FPV drone frames are usually categorized by propeller size ' the biggest propeller they can run. You should always use the intended propeller size on your frame to maximize performance.

Pitch

The second number, such as the 4 in 5x4x3, represents the pitch of the propeller. This refers to how far the prop would theoretically move forward in one rotation if there were no air resistance (measured in inches). It's similar to how a screw moves through a solid material with each turn.

• Low Pitch Props:
  • Easier to spin through the air, enabling quicker RPM changes.
  • Provide more responsive control and generate less propwash vibration.
  • Requires less motor torque and draws less current.
  • Move less air, resulting in lower thrust and top speed.
• High Pitch Props:
  • Move more air per rotation, creating greater thrust and allowing for higher top speeds.
  • Require more torque to change RPM, which can reduce responsiveness if the motor struggles to provide enough power.
  • Typically less efficient than lower pitch props.

How Many Blades?

The third number (e.g., the 3 in 5x4x3) indicates the number of blades on the propeller. Common options include:

• Two-Blade Props: Known for efficiency and low drag, ideal for long-range flying due to reduced current draw and better flight time.
• Three-Blade Props: Offer a balance of thrust, agility, and efficiency, the most popular choice for FPV drones, providing excellent grip and stable performance.
• Four-Blade Props (or More): Generate more thrust and stability but are less efficient, commonly used in small cinewhoops for lifting heavier payloads while maintaining a compact form factor.

Adding More Blades

Increasing the number of blades effectively increases the surface area, allowing the propeller to produce more thrust. This is similar to using a larger propeller but you can fit it in a smaller disk area. However, with additional blades it requires more torque form the motors to spin it. If the motor isn't powerful enough, it reduces responsiveness. It can also reduce your flight time significantly due to the higher current draw.

Common Uses

For FPV drone pilots, both two and three-blade propellers are popular options. Most pilots prefer three-blade propellers for racing and freestyle, as they have a more balanced performance in terms of efficiency and power, they provide more grip in the air due to the extra surface area compared to two-blade. On the other hand, two-blade is usually more efficient as they creates less drag and draw less current, hence they are more popular for long range builds.

There are propellers with more than 3 blades, such as quad-blade, 5-blade and hex-blade propellers. Quad-blade propellers are said to be great for indoor tracks and cornering, but they are less efficient than tri-blade and spin at a lower RPM at a given power. Hex-blade propellers are not recommended for normal flight due to its extreme inefficiency, but micro cinewhoops sometimes use propellers with high blade count to improve power without sacrificing their compact form factor.

Weight

The weight of a propeller significantly impacts drone performance. Generally, lighter propellers offer better performance due to their lower moment of inertia, allowing motors to change RPM more quickly. This makes your drone feel more responsive and nimble. Heavier propellers have more mass on each blade and require a more powerful motor to spin them. This can lead to higher torque loading, making the motor work harder and possibly decreasing overall performance, including responsiveness and efficiency. Lighter props also work better with a wider range of motors because they require less torque to spin up.

The weight distribution of the blades also matters. With the center of mass nearer the hub makes the prop easier to spin and stop, improving responsiveness. However, that means the tip would be the thinner and may be more prone to breaking in crashes. With the weight nearer to the tip, you'd experience greater drag and makes it harder to accelerate or decelerate, reducing agility.

Propeller Rotation

Propellers are designed to spin in a specific direction: either clockwise (CW) or counter-clockwise (CCW). The only exception is 3D props, which can spin in both directions but are used in niche applications.

In a quadcopter, two motors spin CW and the other two spin CCW, so it's crucial to match the propellers to the motors based on their intended direction of rotation.

Fun Fact: Why Two CW and Two CCW?

You might wonder why FPV drones use a mix of clockwise and counter-clockwise propellers.

Two propellers generate CW torque, while the other two generate CCW torque, effectively canceling out the rotational forces. Without this counteraction, the drone would spin uncontrollably in the opposite direction of the motors'much like a helicopter with a damaged tail rotor (a scenario you've likely seen in movies).

Additionally, this opposing torque can be used to create rotational movement for the quadcopter (aka yaw movement).

To determine the direction a propeller should spin, look at its leading edge (the side that cuts into the air) and trailing edge. The propeller's shape and curvature indicate the intended direction of rotation. Some propellers are also labeled with CW or CCW near the hub for easy identification.

If you mount a propeller in the wrong direction, it will push air in the opposite way, causing the drone to flip over or fail to take off.

FPV drone propellers are typically sold in packs of four: two CW and two CCW.

Types of Propeller Mounting

Typical FPV drone motors use one of the three common mounting methods: Prop Nuts, T-Mount, and Press Fit. Each type has its advantages and is suited for specific drone sizes and applications. Make sure you understand which setup your motors use before picking up propellers to avoid incompatibility.

Prop Nuts

Prop nuts are the most common mounting method for 5' FPV drones and larger rigs. The propeller is placed onto a motor shaft with an M5 thread and secured with a self-locking nylon nut.

T-Mount

In T-Mount setups, the propeller is secured to the motor bell using two small M2 screws. The motor shaft, typically 1mm or 1.5mm in diameter, helps center the prop. The lightweight design is ideal for smaller, less powerful drones. It offers a secure fit without requiring large threaded shafts or nuts. This mounting is popular in small 2' to 4' FPV drones.

Press Fit

In press-fit mounting, the propeller is pushed onto the motor shaft using friction to hold it in place. Motor shafts are typically 1mm or 1.5mm in diameter. No screws or nuts are needed, reducing weight and makes changing propeller simple. However, propellers may fly off if the motors spin too fast, or in collisions. This is popular in toothpicks (ultralight) drones and tiny whoops.

Material

FPV propellers are typically made from durable plastic, specifically polycarbonate. This material is lightweight, flexible, and resilient, allowing propellers to bend or warp in crashes without breaking easily. It's an ideal choice for the demands of FPV drones.

There are also propellers made from carbon fiber or wood, which offer increased stiffness and precision. However, these are generally used in planes or larger multirotors that aren't intended to crash, as they are more expensive and prone to damage.

Stick with plastic props'they're affordable, easy to replace, and well-suited for most flying styles.

How to Install Propellers?

Here's a step-by-step guide to properly installing propellers on your FPV drone:

1. Check Motor Orientation

By default, Betaflight expects the motors to spin in specific directions, as shown in the diagram below (you can also find this diagram in the Motors tab in Betaflight Configurator).

• Install CW props on the front-left and rear-right motors.
• Install CCW props on the front-right and rear-left motors.

Pro Tip: To make it easier to remember, all front props spin toward the FPV camera, while rear props spin toward the back of the drone.

2. Identify the Top and Bottom of the Propeller

• The top side of the propeller is often glossy or shiny, and near the hub, it may feature extruded text like the model or size numbers.
• The bottom side typically has a matte finish.

Make sure the glossy/text side faces up when installing the propellers. If the props are mounted upside down, the drone's performance will be severely reduced'or it might flip over when you try to take off.

3. Match Propellers to Motors

Ensure CW propellers are mounted on CW motors, and CCW props are mounted on CCW motors. Incorrect installation can cause the drone to flip over when taking off.

4. Secure the Props

Attach the props securely using the provided screws, lock nuts, or other fasteners. Loose props can fly off mid-flight, leading to a crash.

5. Double-Check Installation

Spin each propeller by hand to confirm it is installed in the correct orientation. When spinning, each prop should push air downward.

Understanding Props In and Props Out

FPV drones can be configured in two ways: props in or props out, depending on the direction the propellers spin. The default configuration in Betaflight is props in, and if you reverse the directions of all 4 propellers, it's props out.

This configuration affects airflow and how debris is thrown away from the drone. You can learn more about the benefits and trade-offs of each configuration in my detailed guide: https://oscarliang.com/reversed-motor-prop-rotation-quadcopter/

Pusher Configuration

The pusher configuration is common in Cinewhoops, where the motors are mounted upside down, and the propellers 'push' air upward instead of pulling it down.

This configuration does not affect how props are mounted. You still follow the same rules for matching CW and CCW props with the correct motors based on their rotation direction.

Learn more about the pros and cons of pusher configuration here: https://oscarliang.com/pusher-configuration-explained/

How to Choose Propellers

Here is a table that shows which size propeller to use with different motors and voltages..

FPV drone sizes are typically categorized by the maximum propeller size that can be used in that frame. The most popular FPV drone size is probably 5-inch due to its versatility, as it can be used for racing, freestyle, cinematic and long range. It can comfortably carry a full-size GoPro camera, thus it's often used for capturing cinematic shots as well. The 7-inch builds are more suited for long-range flights because it can carry a much larger battery and the larger 7' propellers are often more efficient that smaller 5'. I  won't go into too much detail here, you can learn about all the different drone sizes in this post.

Thrust

Thrust is measured in grams. For your drone to hover, the propeller needs to produce at least 1 gram of thrust for every gram that your drone weighs. To perform stunts, or even just to take off or fly forward, your drone needs more than 1 gram of thrust per gram of weight.

Propellers produce more thrust when they spin faster and less when they spin slower. The speed of the drone also affects the amount of thrust produced. Some props perform well when the drone is stationary, but not so well during a cruise, while others perform well at high speeds but poorly when hovering. You want a prop that balances these factors and can create a good amount of thrust at different speeds.

To find the best prop for your drone, look up motor thrust tests to see what prop size work best with your motor. Keep in mind that props perform wildly differently when strapped to a thrust stand in a static setting compared to when they're actually flying through moving air. Props can produce 20-30% less thrust in the air than on the ground.

To accurately assess prop performance, it needs to be tested at the speed your drone normally flies at. However, few people have access to wind tunnels for this type of testing. So, take performance tests with a grain of salt as they may not be an accurate representation of real-world use.

Smoothness

In the hobby, people often use the term 'smoothness' to describe the quality of a motor or propeller. It's not something that can be measured quantitatively, but more of a feeling that pilots have. In my experience, lower pitch props tend to be smoother because the motor can change RPM more easily and quickly. This allows the drone to respond faster to correct errors and reduces something called 'prop wash'.

Speed

A propeller that creates lots of thrust with high pitch doesn't necessarily make a drone faster than a lower pitch propeller that generates less thrust. As the propeller's speed increases (which is measured in rotation per minute ' RPM), so does the drag, requiring more torque from the motor to turn.

The theoretical maximum speed of an aircraft can be calculated using the equation:

Max Speed (in inch per second) = Max RPM * Propeller's Pitch / 60

In real life, factors such as air resistance, head wind, and angle of attack etc can all affect a drone's speed.

Thrust affects acceleration and angle of attack, while RPM affects top speed. To achieve the best speed for your FPV drone, you need a balance between thrust and RPM.

Are Larger Props Better?

1. Responsiveness: A larger prop means a higher moment of inertia, leading to reduced responsiveness. This is particularly noticeable when using motors that typically drive 5-inch props like the size. On these motors, a 7-inch or even 6-inch prop will be less agile in responding to quick, sharp control inputs compared to a 5-inch prop. You will need a bigger motors to compensate but it will add weights and requires more powerful battery and electronics.

2. Thrust and Efficiency: Larger props generate more thrust, making them more efficient ' they can carry more weight, even with the same motor. The increased efficiency means you get more thrust for the same power or the same thrust at a lower power requirement.

3. Vibration: As you increase prop size, expect more vibration. This is amplified by larger, less stiff frames.

4. Top Speed and Prop Wash Handling: Larger props tend to have a lower top speed but better prop wash handling. However, they are often more efficient, capable of maintaining higher speeds over longer periods.

Goto Rayi to know more.

Angle of Attack

The angle of attack refers to the angle at which air meets the propeller blades during flight, and this can significantly influence the efficiency of your propellers based on your drone's attitude and speed.

Hovering and Low-Speed Flight

When a drone is hovering, the airflow is primarily vertical, and the propeller blades rely on their pitch to generate thrust. A lower pitch propeller is generally more efficient in this scenario, as it moves air smoothly without requiring high torque. For example, if the pitch is too high (e.g., close to 90 degrees), the propeller ends up 'slapping' the air rather than efficiently displacing it, resulting in wasted energy and reduced thrust.

Forward Flight and High-Speed Cruising

As the drone tilts forward to fly, the angle of attack changes, and air begins entering the propeller blades at an angle rather than directly from below. At this point, Higher pitch propellers become more effective because they are better suited to displacing air in forward motion. They generate more thrust with each rotation, making them ideal for drones that maintain high cruising speeds or need quick acceleration. If your goal is to cover long distance instead of long flight time, trying some higher pitch props might be a good idea.

Finding the Optimal Setup

It's just a generalization, it's absolutely necessary to experiment with different props to find the optimal setup for your specific drone setup and flight style.

Weather and Temperature

Cold weather poses significant challenges for drones. As explained in our guide 'How to fly FPV in the winter', not only does it negatively impact battery performance, but it can also affect propellers. Depending on their material, propellers may stiffen and become brittle in cold temperatures, increasing the likelihood of breaking upon collision.

Impact of Altitude

Altitude can drastically affect air density and, consequently, the performance of your FPV drone. In areas of lower air density, such as high altitudes, you'll experience less thrust from the same motor RPM. This results in the drone feeling more sluggish and less powerful, similar to the effect of using lower-pitch propellers. Therefore, when flying at high altitudes, it's advisable to use higher-pitch propellers to compensate for the reduced air density.

Impact on Tuning

Changing propellers can have an effect on your drone's PID and filter tuning. Props of different design, size, pitch or blade count will have effect on RPM, throttle/thrust linearity, vibration etc.

Say if you are just swapping out the HQ 5×4.3×3 with some Gemfan Hurricane , it'd probably still be flyable, but if you are a perfectionist you probably want to tune your quad for a specific type of props.

The difference is even more pronounced when you use props of completely different size or blade count. For instance, 2-blade propellers tend to have a stronger 2nd harmonics in motor noise band, while for 3-blade the 3rd harmonics is usually stronger than the 2nd.

Noise Considerations

The noise and sound profile of propellers is an often-overlooked aspect when selecting props for your FPV drone, but it can significantly impact your flying experience'especially in urban areas or indoor.

Factors That Affect Propeller Noise:

1. RPM (How Fast It Spins): Higher RPM creates higher-frequency noise, often perceived as a loud whine. Some cinewhoop would use props with a higher blade count in order to reduce RPM while maintaining the same thrust output, which can result in a quieter drone at the cost of efficiency.
2. Propeller Design: The shape, pitch, and surface area of the blades affect airflow and noise. Wider or thicker blades may create a deeper sound, while thinner blades can be more high-pitched. Toroidal props have a unique shape that produces a softer, more pleasant sound profile to the human ear. Learn more about them here: https://oscarliang.com/toroidal-propellers/
3. Frame Design: Cinewhoops, with their ducted frames, are particularly noisy due to the way air is pushed through the ducts at high RPM. Open-frame designs generally produce less noise in comparison.

Final Thoughts

Propellers are one of the easiest and cheapest components to experiment with on an FPV drone. By understanding the basics of size, pitch, blade count, and material, you can choose the right props to match your flying style and drone setup. Don't be afraid to try different combinations and see what works best for you.

Happy flying!

Edit History

The ultimate outcome of all your expense and effort when building a new homebuilt airplane is going to be the performance delivered by the propeller attached to your engine. Choosing a propeller type and supplier can be as simple as following the recommendation of the original designer or as complex as sifting through websites and input from fellow builders. In our annual roundup of propeller companies, we'll try to update information and developments from the broad array of prop suppliers and revisit the subject of propeller design to help guide your choice.

If your homebuilt project is going to use a certified engine, you may feel the need to stay with an FAA-certified propeller, which limits your choices to the major U.S. manufacturers of such props'Hartzell, McCauley, Sensenich'and the foreign companies that have gained reciprocal certification, such as MT-Propeller. On the other hand, aside from perhaps shortening the Phase I flight testing period, there's no pressing reason to go with a certified propeller on your homebuilt. The non-certified propeller route offers many more options, including some Experimental-category props offered by traditional certified propeller makers. From those crossover models, your search can also lead to propeller suppliers who have no interest in offering certificated props, preferring to concentrate solely on the Experimental market.

The ultimate Experimental-category propellers are the custom-made props created for your particular engine and airframe combination. If you give custom prop builders your horsepower and speed range, they can create a special propeller just for your aircraft. In some cases this may involve a bit of tweaking to bring it right into the performance slot you desire, matching it exactly to your real-world operating regime.

Propeller Progression

Starting at the basics, a simple fixed-pitch two-blade airscrew will keep the cost down and simplify installation. Your engine may have been set up to only accept such a primitive device. A fixed-pitch propeller can be made of laminated wood, forged aluminum or composite materials with various core constructions. Fixed-pitch means you'll have to live with the performance compromise inherent in the pitch that's built into the blades. Engine rpm changes as airspeed varies unless the throttle is continually adjusted.

Propeller pitch is akin to an automotive transmission's gearing ratio: With only one 'gear,' your fixed-pitch propeller will likely be targeted more toward level cruising flight, where the airplane spends most of its time, to the detriment of takeoff and climb performance. However, there is a 'sweet spot' range for a given blade pitch within which performance deteriorates by 10% or less from an optimum pitch. Some prop builders claim their blades have the ability to flex under load to achieve some shift in pitch that gives better performance than a true fixed-pitch blade.

Experimental aircraft frequently utilize ground-adjustable propellers, with blades that can be rotated in a special hub mounting, enabling their pitch to be tuned to deliver maximum thrust at a certain airspeed. Such technology dates from the s, when adjustable steel and aluminum propellers were widely used. Once the adjustment is set, you'll have a fixed-pitch propeller until you can land and readjust the blade settings. Seldom do builders change the pitch once its proper setting is determined.

Of course, pilots would rather be able to adjust the propeller pitch in flight, leaving it in a low pitch setting for takeoff and initial climb, then dialing it toward higher pitch to keep the engine from over-revving as airspeed increases in level flight. Such in-flight adjustments usually require intermittent activation of an electric motor to precisely toggle the desired engine rpm. Some motorgliders, aka self-launching sailplanes, have three-position manually adjustable propellers that are shifted with the engine at idle, offering climb, cruise and feathered (engine off) positions. Adjustable propellers perform as fixed-pitch devices once set, so there will still be rpm changes as airspeed increases and decreases during maneuvering flight.

Naturally, more capability is always better, so the next step in complexity is to add a governor to the pitch-change mechanism, constantly varying propeller pitch during flight so engine rpm is held steady despite throttle and airspeed changes. Constant-speed propellers are complex devices and require a means of imparting the pilot's desires to the propeller, through either electricity or oil pressure delivered to the prop hub. Having more moving parts to wear out means maintenance is inevitable. Also, the extra up-front weight of the constant-speed prop and governor has to be taken into account.

Multi-engine airplanes require a means of stopping the propeller to reduce drag in the event of an in-flight engine failure, hence the feathering propeller was invented to stop a windmilling propeller from being a giant air brake. And for times when adding even more drag would be desirable, as during landing rollout, someone came up with reversing propellers, applying engine power for braking.

Seeking More Benefits

There's something to be said for simplicity. Failure is unlikely to occur in an item of equipment that's not installed, and keeping extra weight off the aircraft is always desirable. Many owners would like the look of a three-blade prop, mistakenly expecting some benefit from performance enhancement. For most small homebuilts, a two-blade propeller is more efficient. Adding blades should only be done if extra horsepower needs to be harnessed; generally speaking, a tri-prop gives more starting torque for takeoff and sounds better, but it'll require masterful reengineering to offset the inherent loss of performance over a good two-blade propeller, and there's usually a weight penalty.

I recently encountered an Experimental airplane owner who wasn't satisfied with his homebuilt's 180-hp Lycoming O-360 engine, so he spent big bucks taking off the carburetor and installing an aft-mounted fuel injection system. On top of that, he replaced the fixed-pitch propeller with a constant-speed version, something never envisioned by the original kit designer, which required considerable cowling modification. One hopes he considered the effect of the added forward weight.

All airplanes are compromises, and propeller choices are part of the equation when it comes to designing for performance targets. It's always best to go with the kit supplier's propeller recommendation and use a propeller type that's been found to be correct for your engine installation.

As in past years, we've compiled the latest information on propeller suppliers. Here are our listings for .

Certified Propeller Manufacturers

Company Founded Certified/
Experimental Origin Construction H.P. Range GT Propellers Certified Italy Wood and composite 80 to hp Hartzell Propeller Inc. Certified U.S.A. Metal and composite Up to hp McCauley Propeller Systems Certified U.S.A. Metal and composite 100 to hp MT-Propeller USA, Inc. Certified Germany Natural composite 65 to + hp custom Sensenich Wood Propeller Co. Certified U.S.A. Wood and composite 50 to 275 hp Sensenich Propeller Mfg. Co., Inc. Certified U.S.A. Metal 65 to 200 hp

GT Propellers

At press time, we had received no reply to a request for an update on GT Propellers, based at Rimini in northeastern Italy. Relying on previous info, we can only quote their website: Italian propeller maker GT Propellers offers wood-core carbon-fiber props in two- to five-blade designs, in fixed, ground-adjustable and constant-speed applications. They've had a 30-year relationship with Tecnam Aircraft, using GT props in Rotax engine applications.

Hartzell Propeller Inc.

Now a part of a newly formed Hartzell Aviation umbrella that also includes exhaust and engine mount repair and fabrication, as well as the engine accessories division, Hartzell Propeller is the flagship component of Hartzell Aviation. In business for well over a century, Hartzell Propeller continues to develop robust propellers for Experimental aircraft.

Currently, Hartzell is featuring the Explorer, a three-blade carbon fiber prop for cross-country cruising with Lycoming 320/360/390 engines and some 540s as well. For STOL work, the Pathfinder three-blade composite-blade model works well on select Lycoming 360 and 390 engines, and for backcountry and floatplane operators Hartzell offers its Trailblazer two- or three-blade prop for certain Lycoming 360 through 580 powerplants. Hartzell's popular Blended Airfoil propeller, used on many kit airplanes for cross-country flying, is a two-blade constant-speed aluminum prop with swept-tip blades for most 360 and 390 Lycomings. For the next generation of aerobatic propellers, Hartzell offers the Talon carbon-fiber two- or three-blade propeller, usable on select AEIO-360, 540 and 580 Lycoming engines.

McCauley Propeller Systems

As a wholly owned division of Cessna Aircraft for the last 62 years, continuing as part of Textron Aviation Inc., a Textron Inc. company, McCauley has been in the aluminum-blade propeller business since . It's now focused largely on supplying original-equipment props for the Textron fleet and marketing the Blackmac brand of STC'd retrofit products. There are over 350,000 aircraft with McCauley propellers out there in service, so if you wind up with a used McCauley constant-speed prop on your project, it'll be well supported.

MT-Propeller USA, Inc.

While of German origin, the MT-Propeller line of 'natural composite' props is supported in North America through a company-owned service center in DeLand, Florida. MT offers a wide variety of constant-speed propellers for single-engine planes as well as feathering and reversing systems for piston and turbine twins. Recent STC approvals were five-blade propellers for the King Air 300/350, three-blade props for Piper's PA-34-200 and a five-blade propeller for the turbine-conversion Cessna 206. Last September, MT-Propeller flew experimental 11-blade propellers mounted on a Piper Cheyenne.

Sensenich Propeller Company

A major U.S. propeller maker dating back some 90 years, Sensenich started out in Pennsylvania, where it still makes its aluminum props, but it now operates as one company with two divisions, building its traditional wood fixed-pitch products and modern composite designs in Plant City, Florida. Airboat propellers are a major market for Sensenich, which explains its southern plant, and it covers the Experimental aircraft arena with ground-adjustable carbon-fiber STOL propellers. Engine installations include ULPower, Jabiru and Rotax, plus Lycoming O-320 and O-360 engines in Van's RVs, Bearhawk, RANS and Zenith STOL designs. Sensenich's latest type certificate approval is for its ground-adjustable carbon-fiber prop in 125- to 180-hp installations. An 82-inch-diameter version is STC'd for the Piper PA-18 with 180 hp.

Non-Certified Propeller Manufacturers

Company Founded Certified/
Experimental Origin Construction H.P. Range Airmaster Propellers, Ltd. Experimental New Zealand Metal/composite 80 to 300 hp AXSport Aviation Experimental South Africa Carbon composite 80 to 200 hp Arrowprop Company, Inc. Experimental U.S.A. Composite Up to 100 hp Bolly Aviation Experimental Australia Composite Up to 160 hp Catto Propellers ASTM and Experimental U.S.A. Composite 65 to 300 hp Competition Aircraft, Inc. Experimental and ultralight U.S.A. Composite Up to 100 hp Culver Props Experimental U.S.A. Wood Up to 300 hp DUC Propellers USA Experimental France Composite 40 to 180 hp E-Props Propellers Experimental and ultralight France Composite 150 to 250 hp GSC Systems, Ltd. Experimental Canada Wood 35 to 115 hp Hercules Propellers Experimental U.K. Wood Custom Hoffmann Propeller GmbH Co. KG EASA and Experimental Germany Wood/composite Up to 500 hp Ivoprop Corporation Experimental U.S.A. Composite Up to 700 hp KievProp America Experimental Ukraine Composite 40 to 180 hp Performance Propellers USA, LLC Experimental U.S.A. Wood 50 to 300 hp Peszke S.C. Experimental Poland Composite Up to 160 hp Powerfin Propellers Experimental U.S.A. Composite Up to 160 hp PowerMax Propeller by TL Ultralight EASA and Experimental Czech Republic Composite Up to 115 hp Prince Aircraft Company Experimental U.S.A. Wood and composite 100 to 300 hp Edward Sterba Propeller Company Experimental U.S.A. Wood 30 to 200 hp Sterna Aircraft Experimental U.S.A. Composite 30 to 450 hp UltraProp (see Competition Aircraft) Warp Drive, Inc. Experimental U.S.A. Composite Up to 180 hp Whirl Wind Propellers Corp. Experimental U.S.A. Composite 80 to 400 hp Woodcomp Propellers EASA and Experimental Czech Republic Wood and composite Up to 310 hp

Airmaster Propellers, Ltd.

In business since , New Zealand-based Airmaster Propellers specializes in electrically controlled constant-speed propeller systems, using composite blades from Sensenich and Whirl Wind mounted in Airmaster's own hubs. Selecting preset takeoff, climb and cruise parameters or a manual rpm setting, the pilot has full command of the propeller's operation via a panel-mounted controller. Airmaster's Martin Eskildsen pointed out that they now offer three- and four-blade propellers for Rotax 915 installations.

AXSport Aviation

Based in South Africa, AXSport markets an aerobatic airplane of its own design, but also has been in the propeller business since , selling three-blade carbon-fiber electric constant-speed props for Lycomings up to 200 hp and Rotax engines up to the 915. Stainless-steel erosion strips for the leading edges are standard. A color-screen cockpit control is being developed for availability.

Arrowprop Company

Arrowprop of Meeker, Oklahoma, builds custom composite propellers for light aircraft using engines of up to 100 hp. Diameters are available up to 72 inches. Focused on ultralight-type and small Experimental aircraft, Arrowprop has been in business since . Initially making wood propellers, they now only use composite technology.

Bolly Aviation

Australian-based Bolly Aviation concentrates on making carbon-fiber propellers for LSAs and ultralight aircraft with up to 160 hp. They provide ground-adjustable props of two-, three- and four-blade configurations, fitted with Bolly's Dura-Tuff leading edge protection. The Optima Series 3 units are for engines with reduction drives, while the Series 5 props are designed for direct drive applications.

Catto Propellers

For nearly 50 years, Catto Propellers has been a noted propeller supplier for Experimental airplanes. Their props utilize a maple wood core encapsulated with fiberglass and carbon fiber, primarily fixed-pitch in two- and three-blade styles. However, Catto does have a constant-speed propeller suitable for the Berkut and Velocity canard aircraft and for Super Cub-type bush planes. Leading edge protection can be either a replaceable polyurethane tape or a nickel leading edge. Catto Propellers is located in Jackson, California.

Competition Aircraft, Inc.

Longtime maker of UltraProp propellers for trikes, powered parachutes and ultralights, Competition Aircraft, located in Hurricane, Utah, has composite ground-adjustable props in two- to six-blade configurations. They can ship immediately from hubs and blades in stock.

Culver Props

For true artwork, a custom-carved two-blade wood propeller is a visual treat. Alaina Lewis and her crew at Culver Props in Rolla, Missouri, can make you a propeller worthy of your replica antique homebuilt, if you're willing to wait. She reported a three- to four-month lead time when we talked, an improvement over the yearlong backlog Culver was experiencing during peak times. Much of their business is in 'wall hanger' decorative propellers, executed in beautiful laminated birch, mahogany and maple woods.

DUC Propellers USA

Based near Lyon in southeastern France, DUC Propellers has a North American office on the Sebring, Florida, airport. DUC offers a wide range of light aviation propeller styles in its Flash, Swirl, Windspoon and Flair designs. A Forged Carbon blade process is used for two- to five-blade props, which are ground-adjustable and available with electric or hydraulic in-flight pitch control. SportairUSA in North Little Rock, Arkansas, is a dealer for DUC as well.

E-Props Propellers Company

E-Props Propellers, located in southeastern France, reportedly produces 45,000 propeller blades per year for Light Sport Aircraft, claiming to be the lightest propellers in the world. New this year is its Glorieuse three-blade carbon constant-speed prop with titanium leading edges, targeted for Rotax 9 series engines up to 140 hp, with a total all-up weight of 8.8 pounds. ASTM-certified E-Props are flying in 84 countries, according to company President Anne Lavrand.

GSC Systems

British Columbia-based GSC systems uses clear eastern maple to craft its propellers for ultralights, trikes and PPCs, in two- and three-blade styles. The Tech II and Tech III props are all ground-adjustable, with individually replaceable blades in case of damage. An inlaid leading edge is optional. Downsized GSC propellers are even showing up on drones, representing a new market for the company.

Hercules Propellers

Hercules Propellers' Rubert Wassey makes fine laminated-beechwood propellers at Stroud, in south-central England. Replica props for antique airplanes and warbirds are a specialty, keeping these vintage birds airworthy. Each Hercules propeller is custom CNC machined for a specific application, incorporating a 'Hercuthane' leading edge shield. When visiting their website, don't forget to click on the expanded contact port in the upper left corner. It's well worth browsing.

Hoffman Propellers, GmbH

Even though it did not respond to our inquiries, the Hoffman Propeller firm in Germany is known to make excellent wooden/composite propellers for a wide variety of aircraft.

Ivoprop Corporation

The Ivoprop is long known for its electrically actuated internal cam, giving the pilot the ability to change pitch in flight to optimize performance in different phases of flight. The carbon graphite fiber construction allows twisting action of imbedded rods in the blades, giving the pilot the ability to manage engine rpm as desired. Ivoprop's Medium series can handle up to 150 hp, with the Magnum series carrying up to 700 hp. Stainless-steel leading edges provide erosion protection.

Kiev Propellers

Started 50 years ago making wood propellers, Kiev props are currently using autoclaved composite blades mounted in ground and in-flight adjustable hubs. Understandably, the terrible wartime conditions in Ukraine have taken a toll on shipments of both raw materials and finished product, but the Kiev factory is operating and propellers are being made, we were told. Ted Bryant at KievProps America in Cambridge, Maryland, the importer for all of the Americas, says they were stocked up in late and were able to ship from inventory up through July . His large orders were being filled and product was being received when we talked in November . All 12 workers at the plant in Ukraine were safely back from military duty and making propellers.

Kiev Props are designed for reduction-drive engine installations only, from 40 to 200 hp, using two- to six-blade styles. Blades are rated for an eight-year service life, with no hour limit, and hubs are rated for 15 years.

Performance Propellers USA, LLC

Located in the suburban Chicago area at Yorkville, Illinois, Performance Propellers has a 35-year history of making custom two- and three-blade wood propellers. One of its specialties is making props for Verner radial engine installations. Each propeller is created for a specific customer need and tweaked as needed for optimum performance. Business at Performance Props was booming, we were told, with lead times of up to a year, so it's best to place your order early in the project.

Powerfin Propellers

Primarily supplying prepreg carbon fiber propellers for ultralights, trikes and powered parachutes, Powerfin is located in Hurricane, Utah. It has two- to five-blade hubs to serve installations of up to 160 hp, offering optional custom blade colors. The low inertia of the Powerfin props helps prolong reduction gearbox life, according to the company.

PowerMax Propeller by TL Ultralight

The PowerMax propeller is built by TL Ultralight, builders of the Sirius, Sparker, Stream and Sting European ultralight aircraft in the Czech Republic. A three-blade carbon fiber propeller that's in-flight adjustable, fitted to Rotax 9-series engines, the PowerMax is represented by SportairUSA in Little Rock, Arkansas, which also distributes TL airplanes.

Peszke S.C.

A Polish company that's been in the propeller business since , Peszke makes a B-Line three-blade carbon-fiber propeller with blades mounted in an aluminum hub, suitable for up to 160 hp, according to company literature. Other products are folding motorglider props and lightweight props for trikes, gyros and ultralights. Owner Jerzy Peszke is seeking a U.S. distributor.

Prince Aircraft Company

Lonnie Prince reports a 10-month backlog in his order book, still making his trademark P-Tip wood/composite propellers at his plant in Whitehouse, Ohio. The P-Tip's small winglet tip design adds effective blade length without sonic stress, and Prince's scimitar-shape props reportedly can twist to change pitch with altered airspeed. A special elliptical-tip blade design for Hummel VW engine installations is also a popular Prince Aircraft propeller product.

Edward Sterba Propeller Company

From one of the great names in custom wood propeller building, we received the following response when we contacted Ed Sterba: 'I have ended my propeller business this past May, after 42 years. It's been a great business, with great customers. Just about props, all handmade. Thanks for carrying my listing all these years.' What a great legacy!

Sterna Aircraft, LLC

Repeated attempts to contact Sterna Aircraft, makers of carbon-fiber ground-adjustable propellers for light aircraft in Zephyrhills, Florida, have drawn no response, although the website remains active.

UltraProp

(see Competition Aircraft)

Warp Drive, Inc.

In business since , the folks at Warp Drive in Ventura, Iowa, are still making their well-regarded ground-adjustable carbon-fiber propellers, in two- to six-blade configurations. In addition to gyrocopter, trike and PPC applications, Warp Drive propellers are also used on light sport and Experimental airplanes, ranging up to 180 hp.

Whirl Wind Propellers Corporation

Whirl Wind Propellers in El Cajon, California, has been making carbon-fiber props in two- and three-blade designs since , using patented closed-mold net-shape blades. Electro-formed nickel leading edge protection is standard. The 300 series three-blade constant-speed props are targeted for RV-style aircraft with O-320 to O-390 engines, weighing in at just 36 pounds. The 330 series comes in two-blade 72-inch diameter and three-blade 73-inch styles, with the three-blade prop suited for O-360 to IO-540 installations. Standard color is black carbon fiber with a clear coat, but optional white-painted blades with red tips are available.

Woodcomp Propellers

A maker of wood and composite variable-pitch propellers in the Czech Republic, Woodcomp offers a KW-10 constant-speed propeller for engines rated from 200 to 310 hp, as well as a ProPulse aerolastic propeller that is said to deform under load to perform like a constant-speed prop. It also has a KW-30 hydraulic variable-pitch propeller.

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