Traditional propellers are made of high-stiffness metal material. They deform only slightly and are usually designed to work at a constant speed, operating at reduced efficiency at other speeds. This research designs a composite propeller that operates over a wider range of speeds. The deformation of propeller is determined by orientating fibers to produce propellers that are more efficient than those made of metal. First, structural and fluid dynamic calculations are performed to determine the deformation, the fluid pressure, and the performance of the propeller. An optimizing genetic algorithm is then used to determine the best stacking sequence of the propeller; however, if the optimal stacking sequence does not outperform a metal propeller, a predeformed design is then used to solve this problem. A smallest pitch stacking sequence is obtained using a genetic algorithm first, and then the propeller is displaced in the opposite direction to form a predeformed propeller. The predeformed propeller finally meets the demands of optimization and outperforms the traditional metal propeller.
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