Formation and Fabrication of A 3D- Printed Polymer Propeller for Improved Propulsion and Minimal Acoustic Emission: A Comparative Study for Small Unmanned Vehicles

Year : 2025 | Volume : 13 | Special Issue 02 | Page : 252-261
    By

    Shravan koundinya Vutukuru,

  • Shivaprasad S Hiremath,

  • Tirthkumar A Bhati,

  • Shradha Bhusare,

  • Nisha R,

  • Jaganraj R,

  • Chandra Bose G,

  1. Assistant Professor, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
  2. Graduate Engineer Trainee, Alten, Karnataka, India
  3. Material Service management Jr Executive, Lufthansa Technik services, Karnataka, India
  4. Analyst, Capgemini, , India
  5. Graduate Engineer Trainee, Mercedes-Benz, Maharashtra, India
  6. Head of the Department, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
  7. Research Scholar, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India

Abstract

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The current research focuses on a comparative analysis of propeller designs to identify an option that enhances thrust efficiency while minimizing acoustic noise. The study evaluates three distinct types of propellers: the traditional three-blade propeller, the Sharrow propeller, and a novel aero propeller featuring an air foil-shaped cross-section. To facilitate a hands-on analysis, these propellers were produced using 3D printing technology, specifically employing ABS filament through a Fused Deposition Modelling (FDM) process. Each propeller design was subjected to a thorough evaluation to understand its capabilities and limitations. Traditional three-blade propellers have approached their maximum potential in terms of thrust and noise reduction, prompting the need for innovative alternatives. The Sharrow propeller stands out as a promising design, providing improved efficiency and reduced noise levels when compared to conventional models. However, this study introduces the aero propeller—a refined version of the Sharrow design—engineered to further enhance thrust capabilities and reduce acoustic noise. Experimental methods, including smoke flow visualization, thrust generation tests, and noise emission analysis, were employed to gauge the performance of each propeller. The findings revealed that the aero propeller not only performed better in generating thrust but also emitted less noise than the other designs. Additionally, the ABS polymer material used in the 3D printing process demonstrated excellent durability and stability, even under high rotational speeds. The overall results indicate that the aero propeller excels in achieving both higher thrust efficiency and lower noise emissions, making it a superior choice for applications in small unmanned vehicles that require optimized performance. This advancement in propeller design signifies a meaningful progression toward more efficient and quieter propulsion systems.ABS filament material was found to be the most suitable for experimenting all three different propellers.

Keywords: Sharrow propeller, aero propeller, flow visualization; acoustic noise emission; thrust

[This article belongs to Special Issue under section in Journal of Polymer and Composites (jopc)]

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How to cite this article:
Shravan koundinya Vutukuru, Shivaprasad S Hiremath, Tirthkumar A Bhati, Shradha Bhusare, Nisha R, Jaganraj R, Chandra Bose G. Formation and Fabrication of A 3D- Printed Polymer Propeller for Improved Propulsion and Minimal Acoustic Emission: A Comparative Study for Small Unmanned Vehicles. Journal of Polymer and Composites. 2025; 13(02):252-261.
How to cite this URL:
Shravan koundinya Vutukuru, Shivaprasad S Hiremath, Tirthkumar A Bhati, Shradha Bhusare, Nisha R, Jaganraj R, Chandra Bose G. Formation and Fabrication of A 3D- Printed Polymer Propeller for Improved Propulsion and Minimal Acoustic Emission: A Comparative Study for Small Unmanned Vehicles. Journal of Polymer and Composites. 2025; 13(02):252-261. Available from: https://journals.stmjournals.com/jopc/article=2025/view=0



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Special Issue Subscription Original Research
Volume 13
Special Issue 02
Received 24/09/2024
Accepted 18/10/2024
Published 25/01/2025
Publication Time 123 Days
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