Toroidal Propellers for Efficient and Sustainable Aviation
News and updates:
This section is dedicated to recording ongoing communication activities, milestones, and dissemination outputs achieved throughout the course of the TorPropel project. As part of our commitment to transparency and stakeholder engagement, updates will include key announcements, technical achievements, public outreach efforts, conference participation, and press coverage.
The information below will be periodically updated and archived to reflect the evolving story of TorPropel and its contributions to sustainable aviation innovation.
TorPropel Project Kick-off
We are thrilled to announce the successful Kick-off Meeting of TorPropel, an ambitious research initiative focused on advancing aerospace propulsion through toroidal propellers.With a strong consortium of leading industry players, academic institutions, and research organisations, we are working together to enhance efficiency, reduce noise pollution, and promote sustainable aviation solutions.
Consortium Members:​
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University of Ioannina
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Aristotle University of Thessaloniki
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Technical University of Munich
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iCOMAT
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CIDETEC
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GMI AERO
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Brunel Composites Centre (Brunel University of London)
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Limmat Scientific AG
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Evektor
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This marks the beginning of an exciting journey to revolutionise next-generation aviation technologies! Stay tuned for updates on our research, development, and milestones.
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Shaping the Future of Propulsion with Toroidal Innovation
Greetings. I am Roland Furmanek, and I am Aerodynamics and Performance Engineer at Evektor in Czech Republic. Within the TorPropel project, I am responsible for development of Propeller Specifications and Manufacturing Requirements (WP1) and Preparation and Execution of full-scale testing campaign (WP4).
The TorPropel project focuses on the development of a new generation of propellers by the implementation of the toroidal propellers’ technology and novel composite materials based on recyclable and repairable epoxy vitrimers. The idea is to implement various multi-objective optimization techniques to scale up the toroidal geometry with a focus on the propeller performance and noise emissions.
TorPropel aims to develop new composite materials by implementing Rapid Tow Shearing (RTS) techniques. Integrating real-time health monitoring sensors improves aircraft safety and propeller life. The embedded sensors provide crucial data to increase propeller reparability, ensuring rapid and early detection of any major damages (WP3 and WP4).
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The work will start with in-depth research of the toroidal propeller technology and a preliminary assessment of selected solutions (WP1). Following up with the simultaneous development of the vitrimer-based carbon-fiber materials, design, and optimization of the propeller geometry (WP2 and WP3). Completing the material design, the CFD-FEA simulation loop will be executed to maximize aerodynamic performance and ensure a lightweight, rigid structure. The optimized structure will be manufactured with embedded sensors to examine and validate the propeller performance. The testing campaign will conclude by reaching TRL4 and fulfilling the main project goal. (WP4) Finally, based on the learnings, maintenance procedures and recyclability will be established, along with a road map to introduce the propeller to the market. (WP5).​​​​​​​
CSML Leads the Charge in TorPropel as Project Coordinator
The Composite & Smart Materials Laboratory (CSML) at the University of Ioannina, Greece, brings a legacy of excellence in composite materials research to the forefront of sustainable aviation as the coordinator of the TorPropel project. Established in 2007 within the Department of Materials Science and Engineering, CSML has developed into a powerhouse of innovation in functional and structural composites.
With over 500 journal and conference publications, more than 20 national and EU-funded R&D projects, and upwards of €5 million in research funding secured, CSML has cultivated a strong network of collaborators across academia and industry.Within the TorPropel project, CSML plays a dual role of strategic coordination and technical leadership. Leveraging its extensive experience in European project management, the lab ensures smooth execution, timely deliverables, and a unified consortium vision.
Technically, CSML spearheads the design, optimisation, characterisation, and production of vitrimer-based carbon fibre tapes, which will be used to manufacture the novel toroidal propellers at the heart of TorPropel’s innovation. Additionally, CSML’s expertise in non-destructive testing (NDT) and structural health monitoring (SHM) will contribute to the development of an integrated sensing platform, a key element in advancing intelligent and resilient propulsion components.
TorPropel benefits from CSML’s leadership and cutting-edge research, reaffirming Europe’s commitment to greener, smarter aviation technologies.
Partner Presentation: Evektor
We’re proud to introduce Evektor, a key partner in the TorPropel project. With over 30 years of experience in general aviation, Evektor is a leading Czech aircraft manufacturer and a trusted provider of engineering services for the aerospace sectors.​ Their deep expertise in aerodynamic design, structural analysis, and advanced numerical simulations positions them as a vital contributor to TorPropel. As part of the project, Evektor will: ​​- Lead the planning and execution of full-scale propeller prototype tests- Support development through high-fidelity CFD analysis- Provide end-user insight to align technology with market needs Together, we’re rethinking propulsion to make future flight quieter, cleaner, and more efficient.
Partner Presentation: Aristotle University of Thessaloniki
The Laboratory of Fluid Mechanics and Turbomachinery (LFMT) at Aristotle University of Thessaloniki (AUTH) brings extensive expertise in aeronautical engineering, with a focus on the design, development, and testing of novel aircraft propulsion components. In TorPropel, AUTH-LFMT is responsible for the aerodynamic and acoustic optimisation of the toroidal propeller design.
Their role includes the development of an advanced modelling pipeline, combining:
- Computational Fluid Dynamics (CFD)
- Novel optimisation methods
- Machine learning ML techniques
This contribution will be essential to ensuring high performance and low noise characteristics in the next generation of aerospace propulsion.
PARTNER PRESENTATION: CIDETEC
CIDETEC is a leading Spanish applied research organisation specialising in surface technologies, advanced polymers, and sustainable material solutions for sectors such as aerospace, automotive, and energy.In the TorPropel project, CIDETEC is focused on:- Formulating a vitrimer for a recyclable and repairable toroidal propeller- Supporting advanced manufacturing via Rapid Tow Shearing (in collaboration with iCOMAT)- Investigating chemical recycling pathways using controlled swelling and reduction techniques. With extensive facilities and a track record of impactful research, CIDETEC brings critical expertise to enable sustainable, circular composites in aerospace propulsion
PARTNER PRESENTATION: Technische Universität München
The Chair of Carbon Composites at the Technical University of Munich is a globally recognised research center specialising in fibre-reinforced materials. Their experience includes designing composite structures from raw materials to complete products. In the TorPropel project, the University will:​- optimise the toroidal propeller - perform aeroelasticity analysis of the composite structure- manufacture the specialised tools and forms for precise propeller manufacturing.​
PARTNER PRESENTATION: GMI Aero
PARTNER PRESENTATION: iCOMAT
iCOMAT will implement the RTS process to manufacture the Toroidal Propeller prototype and assess the benefits of employment of this groundbreaking technology.
PARTNER PRESENTATION: Brunel Composites Centre
In TorPropel, BCC will select and integrate sensors into propeller blades and perform a detailed life cycle analysis, improving aircraft downtime between overhaul.
PARTNER PRESENTATION: Limmat Scientific
Their contribution leverages:
- Deep expertise in experimental diagnostics
- Engineering-driven performance analysis
- Proven capabilities in aerodynamic optimisation
Their work will directly support the development of quieter, more efficient propulsion systems for future aircraft applications.
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 demand by the application of an external stimulus such as heat, while always maintaining the three-dimensional network. In the activated state, the vitrimer can change shape or react with specific reducing agents, becoming reprocessable, repairable, and recyclable.The TORPROPEL project will produce a toroidal propeller using carbon fibre tapes pre-impregnated with an epoxy-based vitrimer specifically formulated for this application. This means that the propeller will not only be more efficient than conventional metal or composite ones thanks to its toroidal shape, but will also be more sustainable, as it can be repaired if damaged in service and recycled at the end of its useful life.
TorPropel Update: CIDETEC efforts on vitrimer polymers for aviation
TorPropel Update: CIDETEC Hosts Consortium Meeting, July 2025
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 demand by the application of an external stimulus such as heat, while always maintaining the three-dimensional network. In the activated state, the vitrimer can change shape or react with specific reducing agents, becoming reprocessable, repairable, and recyclable.The TORPROPEL project will produce a toroidal propeller using carbon fibre tapes pre-impregnated with an epoxy-based vitrimer specifically formulated for this application. This means that the propeller will not only be more efficient than conventional metal or composite ones thanks to its toroidal shape, but will also be more sustainable, as it can be repaired if damaged in service and recycled at the end of its useful life.
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.By implementing both steady and unsteady simulations, the propeller thrust and torque are simulated and coupled with structural simulations (FEA), feeding a Multi-Objective Optimization algorithm to establish an optimal Pareto solution. Furthermore, in TorPropel project, the CFD is used to perform a detailed analysis of the propeller thrust and propeller wake, studying effects on aircraft control surfaces, improving aircraft efficiency, CO2 pollution, and noise emissions.Below is presented a CFD-RANS unsteady simulation of the baseline propeller; this simulation is used to calibrate the simulation setup with propeller data provided by the manufacturer.
