TorPropel pursues five interconnected objectives to bring toroidal propellers from concept to demonstration. First, the project optimises the scaled-up toroidal geometry, targeting propeller diameters of up to 1.7 metres, through computational fluid dynamics (CFD) and iterative optimisation algorithms, aiming for over 25% improvement in thrust efficiency and more than 15 dB noise reduction. In parallel, the consortium develops bespoke vitrimer-based carbon fibre prepreg tapes that combine aerospace-grade mechanical performance with intrinsic recyclability, and pioneers an automated Rapid Tow Shearing (RTS) manufacturing process capable of producing complex geometries. To ensure operational safety and reduce maintenance costs, TorPropel integrates embedded structural health monitoring (SHM) systems directly into the propeller structure, enabling real-time condition assessment through advanced sensing and wireless data transmission. Finally, the project establishes a comprehensive framework for propeller repairability and recyclability through lifecycle analysis, targeting over 95% material recovery, supporting the aviation industry's transition toward circular economy practices.