Lots of people have suggested 3D printing propellers, but Landru is the first I've seen to do it. Looks pretty good! (I'm not sure I'd trust my old Makerbot with this--he's got a better printer.) He writes:

This is a redesign for an 8040 printable propeller with a 5.5mm (13/64") bore. 

This prop was designed to keep the minimum cross section above .8mm allowing it to be more easily printed, though at a small efficiency loss. 

The propeller will require support on one edge, which makes it very easy to remove. 

I can redesign this for some different center hole diameters if requested, just give me some time as I am pretty busy. 

Here is a short video with the prop on a motor:youtube.com/watch?v=v6yClT12Ges&feature=plcp
I will also be uploading a 5030 prop once it is flight tested. 

I printed mine on a Fablicator using Kisslicer.

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Comment by Maxime Carrier on September 12, 2012 at 8:17pm
That's cool, but I guess it is still cheaper to order them lol

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Comment by John Arne Birkeland on September 13, 2012 at 2:01am

It's a great indication on how the future will be. Just browser and click on a object, and some time later it comes out of the printer.

But frankly, I am having a hard time trusting the current 3D printers for something as sensitive as a propellers. You would not believe the amount of strain a propeller has to endure during flights.

Comment by Rob_Lefebvre on September 13, 2012 at 6:28am

John, I agree.  It's a really interesting concept, and I'd love to be able to make my own props that are custom designed for a multi-rotor.  Similar to those nice CF ones you got, but in 12".  But I also really question how strong they'll be.

Comment by Flying Monkey on September 13, 2012 at 9:37am

Better yet, 3d print the mold! (laser sintered metal anyone?)

Comment by frederic reblewski on September 13, 2012 at 10:07am

for that kind of shape a cnc router seems to be a better option

Comment by Federico Boldori on September 13, 2012 at 11:30am

It is some time that I use my makerbot thing o matic for some parts of my quadcopter. First some minor parts, then i've discovered that ABS can be used for almost everything if used properly. Now i'm testing light motor Mount (quad auw weight is 1.4kg!) long life to 3d print!! :)

Comment by Cre8it on September 13, 2012 at 12:56pm

Wow is this a bad idea.  The cross section of 3D printed parts is very inconsistent.  The parts are very weak especially with thin walls.  Please note in the video that the camera is lined up perfectly so that the camera man has every chance catching a part of a broken prop in their face.

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