In mid-2022, an inquiry from Unmanned Aerial Vehicles (UAV) manufacturer NINANO initiated a collaboration with Mejzlik Propellers to produce precision carbon fiber blades for a custom 30-inch, three-blade propeller system.
The project demonstrated Mejzlik’s ability to translate customer-designed geometries into production-ready components while maintaining structural integrity and aerodynamic accuracy.
Collaboration and Design Scope
NINANO, recognized as one of Asia’s Top 10 companies at the XTC startup competition, develops unmanned systems for logistics, defense, and infrastructure inspection. The company provided a complete 3D propeller model and produced the hub internally, tasking Mejzlik solely with blade manufacturing. This division required exceptionally tight root tolerances to ensure a perfect hub fit.
Material Selection and Manufacturing Approach
Mejzlik engineers determined the internal structure and selected PUR foam for the blade cores after evaluating alternative materials. The team used a wet layup process with custom molds designed for this project. Minor design refinements, such as thickening the trailing edge for manufacturability, were made in coordination with NINANO’s team to preserve aerodynamic intent while improving production reliability.
Prototype blades were sectioned and inspected internally to confirm proper bonding, uniform foam distribution, and precise geometry. The entire development and production cycle was completed in just over three months, accelerated by NINANO’s detailed 3D design data.
Geon-Hong Kim, CEO of NINANO commented “It was a great experience working with Mejzlik to develop our custom-designed propellers. Their extensive experience and expertise, including engineering services such as FEA, were instrumental in helping us achieve our performance goals. The final propellers met our expectations in terms of functionality and efficiency. However, the delivery timeline was slightly longer than anticipated.”
The adjusted schedule reflected the precision required to adapt an external design while preserving geometry and ensuring perfect hub alignment.
Outcome and Future Development
The completed blades supported NINANO’s plans to supply UAV platforms for defense and government applications in South Korea, the United States, and other regions, benefitting from European manufacturing standards and supply chain assurance.
Following the success of the 30-inch propeller, the partnership advanced to a 60-inch version that incorporated FEM analysis to optimize material composition for higher loads and rotational speeds. Continued cooperation and regular development meetings have strengthened the relationship, creating a foundation for future UAV propulsion innovations.
