I am trying to create a mini flying quadrocopter using a Raspberry Pi (mini programmable computer). So far I have hooked up the RPi to 4 motors with controls to each. I'm pretty happy with that side of it.
The part I need help with is the design of the propeller; my motors are not massive and I want to ensure I get the best design for maximum thrust to weight as well as manoeuvrability.
What do I need to look for in propeller design considering my limited motors?
Use Mark Dela's XROTOR - it will give you the chord and twist distribution over span for a given speed, torque and thrust (well, two out of three).
It is based on Larabee's theory (PFD!) for a minimum induced loss rotor.
For a practical solution try to design an optimum propeller for the speed and torque of your motors and then try to find something similar in a hobby shop. Building the propeller yourself will be a major effort - just balancing them well will not be easy.
If you are into doing everything yourself, try to carve a master and make a mold, maybe from silicone rubber. Then you can pour as many propellers as you need. Put glass- or carbon fibers into the mold and fill up with thickened epoxy. For thickening use a mixture of cotton short fibers and Aerosil 200.
The links to the materials are only for background information - I cannot endorse the sources because I have never ordered from those specific suppliers. The method in general will work, though.
