Propeller & UAV/Drone Design

DARcorporation engineers are capable of performing detailed aerodynamic design and analysis on any propeller. Flow characteristics around the propeller rotor can be accurately analyzed and the optimal propeller layout can be determined to ensure superior aircraft performance. The pressure distribution obtained from the aerodynamic analysis is also used in subsequent structural design and analysis for optimal strength and weight of the propeller blades and related structures. DARcorporation can quickly construct propeller prototypes and perform performance testing as well, making DARcorporation a one-stop shop for your propeller design needs. Propeller & UAV Design Brochure.

Aerodynamic Design & Analysis

Based on Blade Element Momentum (BEM) theory, DARcorporation has developed and customized in-house software for initial aerodynamic design of propeller blades. Using high-fidelity CFD (Siemens STAR-CCM+) with rotation simulation, the full power-thrust curve can be constructed. The deliverables of aerodynamic design include recommendations on the number of blades, airfoil selection, chord and pitch distribution, rotor diameter, RPM, etc.

Structural Design & Analysis

DARcorporation utilizes physics-based, high-fidelity Siemens NX Nastran and Autodesk Nastran to analyze the propeller and rotor structures. DARcorporation engineers can perform structural analyses on strength, vibration, fatigue and optimization. Unwanted vibrations are identified and designed out of the system. The propeller is designed in such a way that the natural frequencies of the blades are different from the operating RPM.

Acoustic Analysis and Testing

DARcorporation engineers have the capability to perform analytical analyses of propeller noise. The physics-based high-fidelity simulation tools we use can predict the sound pressure levels at various propeller working conditions. With an on-site acoustic chamber and acoustic testing instruments, we can measure and compare the acoustic/noise signature of different propellers. These measurements allow us to help customers design/select the quietest propeller possible for their aircraft.


DARcorporation has collected and analyzed a large number of commercially available drones and recognized the potential for significant improvement in the area of propeller performance and efficiency, as well as in structural design. Optimizing propeller blades by performing a detailed aerodynamic analysis will ensure that the drone flies longer, farther and more efficiently. Optimized structures will offer the same benefit. The extensive expertise DARcorporation has in aerodynamics and structures can provide any drone with a substantial improvement in propeller performance and overall quality.

Sample Projects

Proposal & Rates

Contact Us

Please contact us for additional information or a detailed proposal. Your detailed proposal will include cost, calendar schedule and estimated man-hours per task. This will be provided at no cost or obligation. We look forward to hearing from you!

Aeronautical Engineering Services: