Document Type
Book Chapter
Publication Date
6-30-2026
Department
College of Engineering; Department of Mechanical and Aerospace Engineering
Abstract
Excessive noise generated by drone propellers remains a major barrier to the widespread acceptance of unmanned aerial vehicles (UAVs), especially in urban and noise-sensitive environments. Traditional approaches to mitigating propeller noise typically replicate bioinspired features such as rigid leading-edge serrations, which only partially capture the complex mechanisms underlying the exceptionally quiet flight of owls. In contrast, this research introduces AeroFeathers, a novel additive manufacturing (AM) technique that enables the direct 3D printing of thin, flexible, hair-like fibres onto propeller surfaces, closely mimicking the compliant, fringe-like structures found in owl feathers. Using low-cost, consumer-grade material extrusion printers combined with customised G-code, we precisely control fibre characteristics including thickness, flexibility, and density—achieving microstructures previously unattainable through conventional manufacturing. Experimental validation in Michigan Tech’s anechoic chamber demonstrates significant aeroacoustic improvements, with reductions of up to 5 dB in overall sound pressure level while maintaining comparable thrust performance to unmodified propellers. By uniquely leveraging flexible fibres rather than rigid serrations, AeroFeathers unlocks a new capability for noise suppression in UAVs. This innovation offers a scalable, accessible pathway toward quieter drones, addressing a critical societal need for reduced environmental noise—with direct benefits for public well-being and health futures—and paving the way for sustainable, resilient infrastructure through a new era of quiet, community-friendly mobility and transportation.
This work was funded by the NASA University Student Research Challenge. Grant number: 80NSSC24K0232.
Recommended Citation
Sharma, B.,
Johnston, W.,
Godakawela, J.,
&
Hardy, K.
(2026).
Chapter 19: AeroFeathers: Biomimetic Propellers with 3D-printed Flexible Fibres for Quieter Drones.
http://doi.org/10.18502/rq457c78_19
Retrieved from: https://digitalcommons.mtu.edu/michigantech-p2/2713
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Publisher's Statement
From the book Prototypes for Humanity: Short Papers Platform Conference Proceedings (DOI: https://doi.org/10.18502/rq457c78)
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