The Function of Aircraft Composite Propellers

A composite apparatus refers to a structure made up of various types of complementary, supportive substances. While individual materials making up a composite mixture may not seem strong and significant, when combined with the right materials, they form a powerful and durable structure.

Composite materials used to create propellers are relatively new to the aviation industry; however, their benefits have contributed significantly to the development of new-generation aircraft and associated components. For their strength and durability, carbon fiber and fiberglass are among the most commonly used composite substances for aerospace applications.

As an industry, aviation and the construction of its related components have both come a long way. Instead of fabricating aircraft from canvas and wood, modern airplanes are crafted using composite materials, whether it be the fuselage, wings, or other miscellaneous parts. As composite materials like carbon fiber are robust, easy to repair, and lightweight, this makes them perfect for implementation as aircraft propellers. This has many aircraft engineers, designers, and manufacturers choosing composite propellers as the standard propeller for their aircraft.

Fabricating a composite propeller blade starts with building a mold by pulling composite materials like carbon fiber socks over a foam core, that of which is applied to the skeleton of the airfoil. A vacuum-assisted transfer process is then used to inject and spread resin throughout the mold, allowing the substance to coat fibers making up the blade. Next, pressure is applied to the mold, and the blade is set to cure for several hours.

Once cured, the molded blade is refined as per the manufacturer's standards. Lastly, for added protection and greater endurance against foreign debris damage, the blade is also covered with a nickel-cobalt erosion shield which is co-moulded and electroformed.

Benefits of Composite Propellers

Lightweight & Durable

In the aviation industry, minimizing aircraft weight will always be a top priority. As compared to aluminum propeller blades, composite blades are considerably lighter and contribute to significant weight reduction in aircraft. With composite material, it is possible for manufacturers to produce thin yet durable airfoils that are capable of withstanding significant wear and tear. Moreover, using composite propellers helps to mitigate the wear of aircraft engines and ultimately enhances their fuel efficiency. As such, one of the quintessential advantages of using composite materials is their long service lives. In comparison, while aluminum blades are easily prone to damages and must be replaced if defective, composite blades can be easily repaired numerous times without impacting their airfoil shape. Additionally, while composite blades might require an initial investment, they help aircraft owners save money over time by reducing flight downtimes. In addition, quick repairs in between overhauls can be made with little-to-no assistance from prop shops.

Cockpit Noise Reduction

A cockpit can be quite noisy due to excess sound produced by powered aircraft, especially those operating with the use of one or more propellers. However, the use of  composite materials helps to significantly lessen their noise production.


If you are conducting maintenance and require composite materials to remedy your repairs, then we at ASAP Aviation Unlimited are here to help. ASAP Aviation Unlimited is a leading parts purchasing platform that offers customers access to numerous products within the defense,  aerospace, and electronic industries. Additionally, our inventory of over 2 billion new, used, obsolete, and hard-to-find parts is equipped with a dedicated search engine, that way customers can look up specific items by NSN, manufacturer, part number, CAGE Code, and more. Take advantage of our Instant RFQ services and experience streamlined sourcing solutions with ASAP Aviation Unlimited, today!


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