Materials & Manufacturing

Technology

Every E-Props propeller is made entirely in France, near Sisteron, by a team of aeronautical engineers and technicians producing hundreds of carbon blades a year — using the same manufacturing rigor across the whole range, direct-drive included.

E-Props 8-axis machining center used for dimensional control and finishing of carbon parts
Manufacturing Process

100% carbon, RTM manufacturing

All E-Props parts — blades, hubs and spinners — are made of carbon and epoxy resin, with a UV-resistant additive (UVA and UVB). They are manufactured using RTM (Resin Transfer Molding), and every part is checked on an 8-axis machining center with laser-scanner dimensional control.

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E-Props titanium leading-edge protection bonded to a carbon propeller blade
Leading-Edge Protection

Titanium leading-edge protection

Every ASCALON blade is reinforced with a titanium leading-edge shield, bonded to the carbon structure to protect against erosion and impact throughout the blade's service life.

Titanium Protection (PDF)
Precision

Balancing & tracking

Two of the checks that keep an E-Props propeller running smooth, quiet, and free of vibration.

Balancing

Perfect balance, every set

Each set of blades is balanced with its own hub and spacer before leaving the workshop. Blades don't need equal mass — what matters for balance is the static moment: how mass is distributed along the blade's length.

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E-Props tracking diagram: maximum 15 mm difference in longitudinal tip position
Tracking

Maximum 15 mm tolerance

Tracking is the difference in longitudinal position from one blade tip to the next. E-Props holds this to a maximum of 15 mm.

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Vibrations

Built to run smooth

E-Props propellers generate very little vibration: they are light, and every one is balanced on a dynamic electronic bench. Pilots may still occasionally notice vibration in flight — it can originate from the propeller, the engine, or the airframe.

For direct-drive engines specifically, every ASCALON also gets a personalized ELIAS vibration survey of your exact installation — see how ELIAS works.