Axalp Technologies has developed and manufactured custom carbon-fiber-reinforced plastic (CFRP) folding propeller blades for Dufour Aerospace’s Aero-200 tilt-wing aircraft, supporting the development of a propulsion system designed to improve efficiency during long-range flight.
The Swiss engineering company designed the blade structure around the Aero-200's folding propeller mechanism, balancing weight, geometry, aerodynamic performance, and structural requirements. Axalp used its in-house design and optimization tools to evaluate the broader propeller system and identify a configuration suited to the aircraft's specific operating requirements.
Axalp subsequently used its rapid-prototyping capabilities to manufacture a batch of custom carbon-fiber blades for Dufour's ground and flight-test schedule. The company's propeller blades typically use CFRP sandwich construction, with carbon fibers tailored within the laminate to achieve a high stiffness-to-weight ratio.
Folding Propellers Reduce Cruise Drag
The folding system addresses a key aerodynamic challenge for tilt-wing aircraft. Large propellers are required during vertical takeoff and hover, but their exposed blades can generate additional drag once the aircraft transitions into forward flight.
For the Aero-200, the outboard propellers fold during cruise, while the inboard pair continues to provide forward thrust. This configuration is intended to reduce unnecessary aerodynamic drag and improve cruise efficiency, potentially supporting greater range during longer missions.
The Aero-200 is being developed for applications including medical transport, search and rescue, and other specialized missions, making efficient propulsion important for its intended operational profile.
The latest development follows earlier testing of the Aero-200's folding propeller system. Dufour has reported initial flights with the folding propellers installed, providing an opportunity to validate the mechanism under real flight conditions and expand the aircraft's flight envelope.
The application also adds to the growing use of composites across the Aero-200 platform. The aircraft incorporates composite structures in areas including the fuselage, nacelles, empennage, and other components, while the new CFRP propeller blades extend lightweight composite construction into the propulsion system.
By combining lightweight CFRP construction with a folding architecture, the propeller system demonstrates how composite materials can support both structural efficiency and aerodynamic optimization in emerging electric and advanced-air-mobility aircraft.
Source: Axalp Technologies | LinkedIn
