Engel Introduces Automated High-Volume Process for Lightweight, Stiff Drone Propeller Blades

Source | ENGEL

In collaboration with multiple partners, ENGEL (Schwertberg, Austria) has developed a scalable lightweight design for drone propeller blades combining unidirectional (UD) carbon fiber tapes with injection molding for a fully automated, high-volume process.

• Load-oriented design: Fiber tapes placed along stress paths enable maximum stiffness at minimal weight

• Integrated production: Tape placement and overmolding in one cycle deliver series-ready speeds

• Functional integration: Structural, acoustic, and mounting features combined in a single part

• Thermoplastic composites advantage: Lightweight, recyclable and suitable for mass production

Why it matters for mobility

This technology accelerates the shift from metal and thermoset composites to fiber-reinforced thermoplastic composites, enabling lighter EV structures, fewer parts and more cost-efficient high-volume composite parts production.

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As composite performance meets injection-molding productivity, applications will expand rapidly across EVs, aerospace, and micro-mobility. ENGEL is helping turn advanced composites into industrial reality, opening new possibilities for scalable lightweight mobility design.

Source | ENGEL LinkedIn post

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