Durability, performance define new generation of propellers
Understanding the carbon fiber composite propeller difference
In the aviation world, composite is a commonly used term. Put simply, a composite is a material made from combining two or more materials with different properties. Composites are typically stronger, lighter, and less prone to fatigue than metal materials, making them ideal for many modern aviation and aerospace applications.
However, with such a broad definition, it's important to understand that not all are equal, especially when it comes to complex technology like aircraft propellers.
The carbon fiber difference
Some propeller manufacturers make their composite blades by wrapping a thin environmental layer of composite material over a laminated wood core. Hartzell Propeller's carbon fiber blades take a different approach to offer uniform strength and integrity. The blades are composed of stainless steel shanks, built-up layers of aerospace-grade carbon fiber, nickel cobalt leading edges, and nickel erosion mesh for unmatched durability.
Aerodynamic advantages
As we know, thicker airfoils produce more drag in flight. Because carbon fiber is up to 10 times stronger than spruce and beech wood cores selected by other propeller manufacturers, Hartzell is able to design wider, thinner aerodynamic airfoils that can still bear the structural load required for optimum aircraft operations. Some of Hartzell's most popular designs include their swept-tip scimitar blade, optimized to yield more thrust and deliver better acceleration and climb performance.
Longevity and repairability
One of the biggest reasons to choose a carbon fiber propeller is to withstand the unforgiving conditions encountered in off-airport operations such as water, snow, ice, gravel, grass, and rocky terrain. While wood core propellers are often susceptible to moisture absorption which can lead to imbalance and a reduction in the strength of the wood, true carbon fiber propellers are suited for the most demanding environments.
If maintenance and repairs are required, the process is surprisingly easy. Rather than filing down material to repair a nick, scratch, or gouge as with aluminum props—or replacing entire blades on wood core props—material can actually be added back to restore a true carbon fiber blade to its original dimensions. Very often, minor nicks, scratches, and dings on Hartzell carbon fiber blades meet the criteria for airworthy damage, allowing for continued flight until minor repairs can be completed on-wing by an A&P or a repairman in a FAR Part 145 shop. This results in reduced lifecycle costs and longer blade life expectancy, providing better long-term value for the propeller investment.
Materials matter: Do you know what you're flying behind?
When evaluating your aircraft propeller options, it's worth asking questions about how the blades are made and what materials are used. It can make all the difference in performance, reliability, safety, and value. The team at Hartzell Propeller offers a wealth of information on their carbon fiber composite propeller blades—including a White Paper—on their website.
Now through the end of 2025, Hartzell Propeller is offering AOPA members a $1,000 discount on carbon fiber composite propeller upgrades through its Top Prop propeller conversion program.
See Hartzell’s composite props in action — Watch: Cleared for Adventure
