Testing Futuristic Propeller Designs on my Solar Powered Boat

rctestflight・2 minutes read

A study comparing different propeller designs found that FDM propellers outperformed SLS and traditional propellers, with bi-blade propellers drawing more power but feeling smoother. Despite potential efficiency gains with toroidal propellers, unbiased data is needed for further analysis in the maritime industry.

Insights

  • FDM printed propellers, post-processed for performance, outperform SLS and traditional propellers, showcasing the potential of additive manufacturing in propeller design and efficiency testing.
  • Despite the efficiency gains shown by toroidal and bi-blade propellers, challenges such as current limits on ESCs and design considerations like pitch angles and airfoil profiles highlight the complexity of optimizing propeller performance, emphasizing the need for further unbiased data and research in the field.

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Recent questions

  • What is the process of replacing a propeller on a boat?

    The process involves removing the old propeller and replacing it with a new one. Different types of propellers, such as FDM printed and traditional propellers, are compared for efficiency. MIT's research on toroidal propellers influencing drone noise sparked interest in propeller design. FDM printers use hot plastic extrusion, while SLS printers use lasers on plastic powder. Post-processing is required for FDM propellers to match off-the-shelf propeller performance. Testing involves swapping propellers on a boat and measuring power consumption to determine efficiency gains.

  • How do FDM and SLS printers differ in propeller production?

    FDM printers use hot plastic extrusion, while SLS printers use lasers on plastic powder to create propellers. FDM propellers require post-processing to match off-the-shelf propeller performance, while SLS propellers have a matte textured surface left as is. Formlabs offered to SLS print toroidal propellers for testing, showcasing the different manufacturing processes used in propeller production. The choice between FDM and SLS printing methods can impact the performance and surface finish of the propellers.

  • What are the design considerations for toroidal propellers?

    Toroidal propellers showed potential efficiency gains in testing but had design considerations like the angle of attack. The bi-blade propeller design was introduced as an alternative to toroidal propellers, drawing more power but feeling extremely smooth without tip vortexes. Detailed analysis of propeller designs revealed issues with pitch angles, airfoil profiles, and cord lengths affecting performance. Despite the potential efficiency of toroidal propellers, unbiased data is called for to further evaluate their performance in comparison to other propeller designs.

  • What factors contribute to boat noise?

    Boat noise is primarily attributed to engine noise and water splashing, not tip vortices from propellers. Running the engine at lower RPM could result in a quieter boat, rather than focusing on tip vortices. The efficiency increase claim of 105% by Chero Marine for their propeller design is substantial, indicating that propeller design can impact noise levels and efficiency. The adoption of toroidal propellers in the maritime industry may be hindered by manufacturing scalability, despite their potential efficiency gains.

  • How does the surface finish of propellers impact efficiency?

    Testing revealed that the surface finish of propellers may not significantly impact efficiency. FDM propellers, sanded and painted with epoxy for a smooth finish, outperformed other propellers in testing. The comparison between FDM and SLS propellers, with different surface finishes, showed that FDM props were the best performers based on data analysis. Experimenting with airplane propellers on boat motors for efficiency revealed potential issues with increased rotational resistance and vibration, highlighting the importance of surface finish in propeller design.

Related videos

Summary

00:00

"3D Printed Propellers: Efficiency and Innovation"

  • The video is sponsored by Factor, a 3D printer company.
  • The process involves removing an old propeller and replacing it with a new one.
  • FDM printed propellers are compared to traditional propellers for efficiency.
  • MIT's publication on toroidal propellers influencing drone noise sparked interest.
  • FDM printers use hot plastic extrusion, while SLS printers use lasers on plastic powder.
  • Post-processing is required for FDM propellers to match off-the-shelf propeller performance.
  • Formlabs offered to SLS print toroidal propellers for testing.
  • Propellers were printed in nylon and had separate hubs for motor shaft attachment.
  • Testing involved swapping propellers on a boat and measuring power consumption.
  • Toroidal propellers showed potential efficiency gains but had design considerations like angle of attack.

12:51

Comparing Bi-Blade and FDM Propellers

  • The bi-blade propeller design is introduced as an alternative to the toroidal propeller.
  • The bi-blade propellers draw 20 watts more power than the toroidal propellers and 40 watts less power than the standard props.
  • The bi-blade props feel extremely smooth and do not exhibit tip vortexes.
  • The FDM propellers, sanded and painted with epoxy for a smooth finish, outperform the other propellers.
  • The FDM props are compared to the SLS props, which have a matte textured surface left as is.
  • The FDM props are noted to be the best performers based on the data analysis.
  • The testing process is refined to include consistent speed control and separate data logging to eliminate errors.
  • The boat's power source includes lithium batteries, solar panels, and a lab benchtop power supply.
  • The toroidal and bi-blade props struggle to reach higher speeds due to current limits on the ESCs.
  • Detailed analysis of propeller designs reveals issues with pitch angles, airfoil profiles, and cord lengths affecting performance.
  • Despite personal testing results, the potential efficiency of toroidal propellers is acknowledged, prompting a call for more unbiased data.

25:09

Propeller design impact on boat noise and efficiency.

  • Boat noise is primarily attributed to engine noise and water splashing, not tip vortices.
  • A quieter boat could result from running the engine at lower RPM, not due to tip vortices.
  • The efficiency increase claim of 105% by Chero Marine for their propeller design is substantial.
  • The adoption of the toroidal propeller design by the maritime industry may be hindered by manufacturing scalability.
  • The patent held by Chero Marine covers both marine and drone propellers.
  • Testing revealed that the surface finish of propellers may not significantly impact efficiency.
  • Experimenting with airplane propellers on boat motors for efficiency is attempted.
  • The use of airplane propellers on boat motors may lead to increased rotational resistance.
  • Vibration issues arise when testing the airplane propellers on boat motors.
  • Analysis of propeller designs through simulation software reveals potential improvements for efficiency.
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