At JEC World 2026, ENGEL demonstrated how it is possible to produce rotor blades for unmanned aerial vehicles from thermoplastic composites efficiently, with consistent quality and fully automated mass production. The global machine tool manufacturer introduced a scalable manufacturing solution that combines high component performance, comprehensive noise reduction and environmental friendliness in a single continuous process.
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| Detail view of a carbon-fibre reinforced composite rotor blade, manufactured near-net-shape using tape-sandwich injection moulding. |
With its expertise in injection moulding and automation, ENGEL is transferring proven high-volume manufacturing principles to lightweight composite applications. At the heart of the exhibit is a highly efficient, integrated process that brings together the key steps – placing the reinforcement layers, forming, functional integration and removal of the finished rotor blade – in a continuous cycle within the injection mould.
Lightweight, strong and near-net-shape: tape-sandwich injection moulding as the core technology
The central element of the demonstrated process is a structural sandwich design consisting of carbon-fibre-reinforced thermoplastic tapes and an injection-moulded short-fibre compound. The tapes form the load-bearing outer layers of the rotor blade and are positioned precisely in the mould and secured using vacuum fixation. This allows the reinforcements to be aligned exactly along the load paths – material is used only where it is needed for structural performance.
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| Drone propeller with carbon-fibre reinforced composite rotor blades manufactured using tape-sandwich injection moulding |
In the next step, the core material made of a short-fibre thermoplastic is injected between the pre-positioned tapes and bonded to the outer layers to form a near-net-shape component structure. To further increase the lightweight potential, the core is foamed chemically, reducing component weight while maintaining structural performance.
The result is a lightweight yet highly durable rotor blade in which shaping, structural function and material bonding are realised in an automated cycle. After a defined final trim, the component is ready for use.
Functional integration and design freedom
One of the key advantages of injection moulding is the high level of design freedom it offers. Noise-reducing features such as serrated trailing edges can be integrated directly into the component geometry using interchangeable mould inserts, without additional machining steps. This makes it possible to address the acoustic requirements of modern drone applications – particularly in urban environments – and reduce noise emissions.
ENGEL demonstrated the process live on a tie-bar-less ENGEL victory 120 injection moulding machine equipped with an easix six-axis robot. The tie-bar-less design provides the space required to fully automate material feeding, handling and part removal. This enables cycle times of less than 60 seconds per rotor blade.
NeoBlade: sustainable development with strong partners
NeoBlade was designed as an interdisciplinary research project spanning the entire value chain. The aim was to link aeroacoustic design, material and tool development, process automation and sustainability assessment at an early stage and translate them into an industrially viable overall solution. Project partners include ALPEX Technologies, the Energy Institute at JKU Linz, FACC Operations, Plastic Innovation and TU Wien (Aircraft Systems Research Group).
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| Injection moulding cell with ENGEL victory and easix six-axis robot – basis of the fully automated production solution for thermoplastic composite rotor blades (front view) |
The project evaluated different thermoplastic systems – from high-temperature-resistant materials to cost-efficient alternatives. Compounds with recycled carbon fibres were also used. Life-cycle assessments showed a significant reduction in CO₂ footprint compared with established thermoset processes. Another advantage is that thermoplastics are generally recyclable: production waste and end-of-life components can be more easily returned to the materials loop.
In addition to sustainability, economic efficiency was also a key focus. The main cost advantage of thermoplastic processes lies in industrial scalability – for example through multi-cavity tooling – combined with very short cycle times and a high degree of automation.
Picture: ENGEL
