• Gabriela Alexandra Badicu Transilvania University of Brasov
  • Sebastian Marian Zaharia Transilvania University of Brasov
  • Mihai Alin Pop Transilvania University of Brasov
Keywords: design, additive manufacturing, helicopter rotor blade, acoustic performance, CFD analysis


In this paper, a blade with unconventional structure, corrugations and BERP tip, used in UAV helicopters, was designed, analyzed and additively manufactured. Aerodynamically, the unconventional blade shows better performance compared to the conventional blade at positive angles of attack. Acoustically, the unconventional blade showed a reduced noise level compared to the conventional blade. Acoustic testing of additively manufactured samples with five honeycomb core configurations showed higher performance for the 1.5 mm honeycomb cell samples 3D printed from T-PLA.


1. Fahlstrom, P. G., Gleason, T. J., Sadraey, M. H. Introduction to UAV systems, John Wiley & Sons, (2022).
2. Lawrence, P., RC Helicopters: The Pilot's Essentials, CreateSpace Independent Publishing, (2017).
3. Rotaru, C., Todorov, M., Helicopter flight physics. Flight Physics-Models, Techniques and Technologies, IntechOpen, London, (2018).
4. Schafer, J., Helicopter Maintenance, Aviation Maintenance, (1986).
5. Federal Aviation Administration (FAA). Helicopter Instructor’s Handbook (FAA-H-8083-4), _policies/handbooks_manuals/aviation/media/FAA-H-8083-4.pdf.
6. Graba, M., Grycz, A., Assessment of the Mechanical Properties of Selected PLA Filaments Used in the UAV Project, Materials Vol.16, (2023).
7. Brocklehurst, A., Barakos, G.N., A review of helicopter rotor blade tip shapes, Progress in Aerospace Sciences, Vol. 56, pp. 35–74, (2013).
8. Marques, P., Maligno, A., Dierks, S., Penev, V., Bachouche, A., The Jinn military unmanned helicopter program: rotor blade tip aerodynamics of the advanced technology demonstrator, International Journal of Unmanned Systems Engineering., Vol.1, No.3, (2013).
9. Song, W., Mu, Z., Wang, Y., Zhang, Z., Zhang, S., Wang, Z., Li, B., Zhang, J., Niu, S., Han, Z. Ren, L., Comparative investigation on improved aerodynamic and acoustic performance of abnormal rotors by bionic edge design and rational material selection, Polymers, Vol. 14, No. 13, (2022).
10. Cao, H., Zhang, M., Cai, C., Zhang, Z., Flow topology and noise modeling of trailing edge serrations. Applied Acoustics, Vol. 168, (2020).
11. Yung, H.Y, Rotor Blade–Vortex Interaction Noise, Progress in Aerospace Sciences, Vol.36, pp. 97–115, (2000).
12. Lacagnina, G., Chaitanya, P., Kim, J.H., Berk, T., Joseph, P., Choi, K.S., Ganapathisubramani, B., Hasheminejad, S.M., Chong, T.P., Stalnov, O. Shahab, M.F., Leading edge serrations for the reduction of aerofoil self-noise at low angle of attack, pre-stall and post-stall conditions, International Journal of Aeroacoustics, Vol. 20, No. 1-2, pp.130-156, (2021).
13. Kessler, C., Active rotor control for helicopters: individual blade control and swashplateless rotor designs, CEAS Aeronautical Journal, Vol. 1, pp. 23-54, (2011).
14. Pakhov, V.V., Fayzullin, K.V. and Denisov, S.L., Measuring the acoustic characteristics of a helicopter rotormodel in a wind tunnel, Acoustical physics, Vol.66, pp.44-54, (2020).
15. Hu, Z., Liu, Y., Shi, Y. and Xu, G., An Experimental Study on Rotor Aerodynamic Noise Control Based on Active Flap Control, Aerospace, Vol. 10, No.2, (2023).
16. Ring, T.P., Langer, S.C., Design, Experimental and Numerical Characterization of 3D-Printed Porous Absorbers, Materials, Vol.12, (2019).
17. Monkova, K., Vasina, M., Monka, P.P., Vanca, J., Kozak, D., Effect of 3D-Printed PLA Structure on Sound Reflection Properties, Polymers, Vol. 14, (2022).
18. Zieliński, T.G., Dauchez, N., Boutin, T., Leturia, M., Wilkinson, A., Chevillotte, F., Bécot, F.X., Venegas, R.,Taking advantage of a 3D printing imperfection in the development of sound-absorbing materials, Applied Acoustics, Vol. 197, pp. 108941, (2022).
19. Monkova, K., Vasina, M., Monka, P.P., Kozak, D., Vanca, J., Effect of the Pore Shape and Size of 3D-Printed Open-Porous ABS Materials on Sound Absorption Performance, Materials, Vol. 13, (2020).
How to Cite
Badicu, G., Zaharia, S., & Pop, M. (2023). DESIGN, ACOUSTIC PERFORMANCE AND ADDITIVE MANUFACTURING OF HELICOPTER ROTOR BLADES WITH UNCONVENTIONAL SHAPES. Nonconventional Technologies Review, 27(3). Retrieved from