News & Updates

What if molds could be produced faster, cheaper, and with far greater design freedom? 💡 Within the TorPropel project, the Technical University of Munich (TUM) applies Large-Scale Additive Manufacturing (LSAM)❗to enable near-net-shape mold fabrication with reduced material consumption and increased design flexibility. Adoption of this technology aims on application in aerospace, automotive and advanced propulsion sectors. The manufacturing process typically begins with large

What happens when propeller designs no longer fit standard aeroacoustic models? At Aristotle University of Thessaloniki (AUTH), within the TorPropel project, we are exploring noise prediction for novel propeller geometries — going beyond traditional benchmark cases. Our work not only evaluates acoustic performance, but also uncovers key trade-offs between noise, efficiency, and other critical design parameters. To predict the acoustic signature of such geometries, we are usin

The greatest barrier to innovation is often the assumption that constraints are fixed... ⛔ Have you ever wondered why propeller design has stayed roughly the same for a century⁉️ Two or three blades, spinning fast, pushing air backwards. It works, but it's noisy, and more often than we'd like, the shape is driven by what's practical to manufacture rather than what's aerodynamically optimal. Toroidal propellers have been around as a concept for over 30 years, the design concep

For decades of last century, the propeller has been the silent workhorse of General Aviation. Reliable, efficient, mechanically simple. Simple blades, aluminium or wood, turning at high RPM - a design philosophy that worked well for generations - was significantly replaced by composite blades, time-tested innovation that works well. 👍 But today, the landscape is shifting. 🚀 Carbon fibre blades are lighter, stronger, more fatigue-resistant. Designers can shape blades now wi

We’re excited to share the latest progress in the production and assessment of the 3R vitrimer prepregs developed for TORPROPEL. The current phase focuses on understanding how these materials behave and optimize them for sustainable fabrication of toroidal propellers for aircraft propulsion. Rigorous characterization is what transforms an innovative material into a reliable aerospace component. TORPROPEL undertakes a comprehensive optimization cycle to assess all relevant man

In the end of January 2026, the TORPROPEL consortium had a fruitful discussion in Paris during face-to-face M12 project meeting. Over two productive days, partners discussed the current project progress, reviewed upcoming tasks and risks (there are always risks), and shared updates from each Work Package. Our wide-experienced specialists exchanged insights focused on vitrimeric materials, sensing technologies, toroidal blades aerodynamic behaviour, manufacturability of rea

Within the TorPropel project, aeroelastic flutter is addressed as a key challenge in the design and operation of advanced aircraft propellers. Flutter is a dynamic instability arising from the interaction of unsteady aerodynamic loads, structural elasticity, and inertial forces, representing a critical limitation for lightweight, high-performance propeller systems. Accurate prediction of flutter behavior is essential to ensure structural integrity, operational safety, and rel

Rotating composite propeller blades of complex toroidal geometry sustain significant centrifugal forces, aerodynamic loads, temperature variations, and fatigue cycles during operation. Traditional inspection methods require grounding aircraft and cannot monitor and capture events during actual operation. In the TorPropel project, Brunel University London - Brunel Composites Centre (BCC) , is developing an embedded sensor network integrated directly into the toroidal propelle

Within the TorPropel project, we are shaping the future of aircraft propellers at the intersection of advanced composite materials, sustainability, and repair-oriented design. Our work focuses on the development of toroidal propellers using innovative vitrimer-based materials, enabling lighter structures, extended service life, and significantly simplified repair processes — all without the need for autoclave manufacturing. Aerospace-grade composites provide exceptional str

The core paradox of engineering design is that by the time you fully understand the system trade-offs, your freedom to act on them has collapsed. In complex engineering cases, the true challenge is never a single goal. It's the balance: efficiency vs. noise, performance vs. weight, innovation vs. manufacturability. This is the field of multi-objective optimization (MOO). The Core Theory: For any system with competing objectives, a Pareto front exists — the set of designs wh

By implementation of the pilot-scale prepreg manufacturing line at the Composites and Smart Materials Lab (CSML) of the University of Ioannina, the TorPropel partners are producing carbon fiber tapes incorporating advanced 3R vitrimer resin. These tapes are specifically engineered for next-generation automated composite manufacturing to address the requirements of the Rapid Tow Shearing (RTS) advanced placement method. This method will be employed to manufacture the project's

An aircraft propeller produces thrust by rotating its blades, which act like small wings with an airfoil shape. As the blades spin, they create a pressure difference—lower pressure in front and higher pressure behind. These pushes air backward (propwash) creating a thrust force, propelling aircraft forward. Unfortunately, during the thrust production the propeller is creating an aerodynamic losses in form of the blade tip vortices. By changing the shape of the propeller to to

Rapid Tow Shearing (RTS) is the world’s first automated composites deposition technology that places wide composites tapes around curved paths without any defects. Effective fibre steering through the RTS head enables rapid manufacture of complex-shaped parts with unprecedented weight and performance benefits, which is not achievable with current techniques. In the Torpropel project, this technology will be implemented to optimize the propeller composite structure by detailed

In the TorPropel project, we are combining the CFD simulation with the Multi-Objective Optimization methodology. The Computational Fluid Dynamics (CFD) simulation is a practical implementation of the Navier-Stokes equations, approximated by the RANS turbulence model to compute an approximate result of the flow field. The CFD methods revolutionized modern aerodynamics and are widely used in the aerospace and automotive industries, from aircraft aerodynamics to heat transfer. B

In recent years, new polymer chemistries based on dynamic covalent bonds have emerged, combining the main advantages of current thermoset resins (thermo-mechanical and chemical resistance) and thermoplastic resins (recyclability and reprocessability). The chemical strategy of these new materials, called vitrimers, is based on introducing plasticity into the cross-linked polymer network through exchangeable chemical bonds, since the exchange reactions can be activated on deman

In recent years, new polymer chemistries based on dynamic covalent bonds have emerged, combining the main advantages of current thermoset resins (thermo-mechanical and chemical resistance) and thermoplastic resins (recyclability and reprocessability). The chemical strategy of these new materials, called vitrimers, is based on introducing plasticity into the cross-linked polymer network through exchangeable chemical bonds, since the exchange reactions can be activated on deman

Limmat Scientific AG is a global leader in hashtag aerodynamic measurement technologies for turbomachinery research, supporting innovation across both the aerospace and energy sectors. In the TorPropel project, Limmat Scientific is responsible for the parametric design of the toroidal propeller blades. Their contribution leverages: - Deep expertise in experimental diagnostics- Engineering-driven performance analysis- Proven capabilities in aerodynamic optimization . Their w

The Brunel Composites Centre (BCC) is a branch of Brunel University, combining the best practices from both academia and industry to serve as a bridge between theoretical and practical knowledge. The Brunel Composites Centre specializes in composites manufacturing, simulations, and life cycle analysis. In TorPropel, BCC will select and integrate sensors into propeller blades and perform a detailed life cycle analysis, improving aircraft downtime between overhaul.

iCOMAT is a world-leading carbon fiber parts manufacturer specializing in the automation of laying down fibers along curved paths. In 2020, the company patented the Rapid Tow Shearing (RTS) method , allowing for the development of lighter and stronger structures. iCOMAT will implement the RTS process to manufacture the Toroidal Propeller prototype and assess the benefits of employment of this groundbreaking technology.

GMI Aero specializes in composite materials repair and maintenance. The company focuses on the development of maintenance equipment and field repairs within hangars and airport-based workshops , providing convenient and time-effective services on and off aircraft. In the TorPropel project, GMI will develop repair procedures for novel vitrimer-based composite propellers , simultaneously improving reliability and cutting maintenance time.