The first real test of mylate-night propeller design and analysis code
It started as a single line of code in September 2025.
Fast forward to today. On May 15th, 2026, have tested on a stand our first manufactured set of fixed-pitch convertible
propellers for a lift+cruise aircraft. They are real. Which I feel as a massive, unbelievable achievement for me.
In this convertible airplane project, with fixed-pitch propellers, we have to cheat physics at least twice: )
To achieve this ambitious goal, my code handles:
- Automated aerodynamic design and optimization: it starts with flight modes, geometric constraints, and engine specs. It
spits out optimal chord distribution, twist angles, and airfoil shapes.
- Lifting line theory: to minimize induced losses, the silent killer of efficiency.
- ML + CASADi for airfoil optimization at three sections.
- BEST calculations (Blade Element Momentum Theory).
- Stress analysis: because a beautiful prop that explodes at max RPM sis just shrapnel waiting to happen.
- NX CAD automation: the code talks to Siemens NX and rebuilds the entire parametric model. Then it puthes that model into
CADFlo for FVA (Finite Volumet Analysis).
- Full visualization and export: graphs, specs, 3D models, and stress heatmaps.
Fast forward to today. On May 15th, 2026, have tested on a stand our first manufactured set of fixed-pitch convertible
propellers for a lift+cruise aircraft. They are real. Which I feel as a massive, unbelievable achievement for me.
In this convertible airplane project, with fixed-pitch propellers, we have to cheat physics at least twice: )
To achieve this ambitious goal, my code handles:
- Automated aerodynamic design and optimization: it starts with flight modes, geometric constraints, and engine specs. It
spits out optimal chord distribution, twist angles, and airfoil shapes.
- Lifting line theory: to minimize induced losses, the silent killer of efficiency.
- ML + CASADi for airfoil optimization at three sections.
- BEST calculations (Blade Element Momentum Theory).
- Stress analysis: because a beautiful prop that explodes at max RPM sis just shrapnel waiting to happen.
- NX CAD automation: the code talks to Siemens NX and rebuilds the entire parametric model. Then it puthes that model into
CADFlo for FVA (Finite Volumet Analysis).
- Full visualization and export: graphs, specs, 3D models, and stress heatmaps.
The "Compromise Propeller" Philosophy
Most props are optimized for one flight condition: takeoff, cruise, or max speed.
We designed a multi-regime fixed-pitch propeller. The code was tasked with finding the geometry that delivers maximum
efficiency across the entire flight envelope. It had to guarantee required thrust at every single mode-hover, transition, and
cruise at various speeds and altitudes.
Static test validation has been completed for both propellers.
For the lift propeller, my BEST analysis combined with the J-ref method for static extrapolation delivered the following
median errors:
By thrust: 6.2%
By
torque: 9.8%
By efficiency: 18.5%
For the lift-cruise propeller, the median errors are:
By thrust: 24.7%
By torque: 15.4%
By efficiency: 10.6%
Looking forward to dynamic wind-tunnel tests of the cruise-lift prop!
Most props are optimized for one flight condition: takeoff, cruise, or max speed.
We designed a multi-regime fixed-pitch propeller. The code was tasked with finding the geometry that delivers maximum
efficiency across the entire flight envelope. It had to guarantee required thrust at every single mode-hover, transition, and
cruise at various speeds and altitudes.
Static test validation has been completed for both propellers.
For the lift propeller, my BEST analysis combined with the J-ref method for static extrapolation delivered the following
median errors:
By thrust: 6.2%
By
torque: 9.8%
By efficiency: 18.5%
For the lift-cruise propeller, the median errors are:
By thrust: 24.7%
By torque: 15.4%
By efficiency: 10.6%
Looking forward to dynamic wind-tunnel tests of the cruise-lift prop!
