Aerodynamic Design and Acoustic Optimization of a Custom 10x6 Folding Propeller

Project Overview

The objective of this project was to develop a custom 10x6 folding propeller for a UAV, addressing specific requirements for thrust, electrical safety, and reduced acoustic signature compared to standard propellers. A "blended airfoil" methodology was employed, integrating distinct airfoil profiles (MH 112, MH 114, MH 116, ARA D) across the blade span to optimize structural integrity, torque generation, and aerodynamic efficiency while minimizing noise. Key design features included an aggressive geometric tip taper and aerodynamic washout at the blade tip to mitigate tip vortex noise. Performance analysis at a 15 m/s climb design point confirmed the propeller's characteristics. The finalized aerodynamic design successfully generated 13.25 N of thrust, exceeding the 1.3 kg target, and maintained power draw within electrical safety limits. The implemented scimitar tip geometry, aggressive chord taper, and aerodynamic washout were engineered to significantly reduce acoustic emissions, fulfilling the project's noise reduction requirement. The design is now prepared for 3D CAD modeling and subsequent CFD validation.