We built thousands of airfoil propellers from 1990 to 2014 for axial fans using the computers to design propellers for a point of operation. Cutting sheet materials for the molds by shingling mat and roving cut on a clicker press with steel rule dies designed for the layers from a computer program we wrote.
The molds were made on a 4X8 "shopbot" from veneered plywood blanks top and bottom and rough cut on the CNC table. A layer of 1-1/2 oz. chop strand mat was layered on top of the plywood and a finishing cut was made. The mold halves were gel coated and polished. FRP makes the best molds since FRP does not stick to cured FRP.
The volume of the prop was calculated by the CAD program and weight and material cost were easy to figure.
The blades were compression molded in hydraulic presses with vents. The prop drawings on my GrabCad posts are from my old drawings and were actually made.
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