2019
Producing the first sample of a composite propeller and repeatedly producing the same geometry with similar mass and performance values are different engineering problems. In 2019, through its work on the 16x5.4 carbon fiber propeller, Tulkas developed a series production methodology alongside the product design.
The core goal of the work was to reduce operator-dependent variability and achieve a similar aerodynamic surface, ply layup, hub connection and mass distribution in every production cycle. For this reason, the process was addressed as a whole — not just through the lamination step, but from mold preparation for production through to final inspection.
For the 16x5.4 propeller, fiber cutting templates, ply order and orientation, root-region reinforcements and the resin application method were turned into standard work steps. Achieving symmetric material distribution on both sides of the blades became one of the key measures reducing the need to later correct balance by removing excess material.
Variables such as mold surface preparation, release agent application, mold closing sequence, cure temperature and duration were defined to be applied in the same order for every production run. Control points were also established for demolding, edge cleanup, center-hole machining and surface inspection after cure.
For rotating parts, it is not enough for the product to simply fit the mold dimensionally. Small mass or stiffness differences between blades can create vibration, bearing load and noise at high RPM. For this reason, static balance, total mass, surface continuity and hub-connection accuracy were added to the end-of-production checklist in the 16x5.4 process.
Inspection results were recorded together with production parameters to evaluate which stage a deviation originated from. This turned quality control from being just a final step that screens out defective parts, into a feedback mechanism that improves the production recipe.
The series production approach developed for the 16x5.4 propeller became one of the core methods for the carbon fiber propeller family Tulkas would later build across different diameters and pitches. Preparation of cutting templates, mold-based production recipes, ply tracking, cure records and balance control were made adaptable to other products.
This work formed one of the important steps toward Tulkas becoming not just a manufacturer of a high-performing prototype, but a composite producer capable of turning a validated product into a repeatable production process.
You can evaluate Tulkas' process development approach to move your propeller or rotating composite part from prototype to repeatable production.
