Single-piece propeller and method of making
A method for making a propeller product is disclosed. The propeller is formed using polyurethane cores adhered to a laminate hub to form a core assembly. An encapsulating structural laminate skin is then formed on the core assembly using a resin-transfer-molding process to create a single-piece composite propeller.
1. An aircraft propeller comprising:
a crush resistant hub core, a first blade core, and a second blade core, said first and second blade cores fixed to said hub core to create a propeller-shaped assembly;
a substantially continuous structural skin formed from a structural braid sleeve saturated in a cured epoxy material, the skin encapsulating the assembly; and
a fastening system for attaching said propeller to a drive mechanism on an aircraft through the hub core.