At JEC World 2026 on March 10-12 in Paris, ENGEL will demonstrate how thermoplastic composite rotor blades for drones can be manufactured efficiently, with consistent quality and fully automated in series production.

Drone propeller with carbon-fiber reinforced composite rotor blades manufactured using tape-sandwich injection molding.

This scalable production solution combines high component performance, integrated noise reduction and sustainability in one seamless process.

Tape-sandwich injection molding as core technology

The central element is a structural sandwich design consisting of carbon-fiber-reinforced thermoplastic tapes and an injection-molded short-fiber compound. The tapes form the load-bearing outer layers of the rotor blade and are positioned precisely in the mold 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.

Detail view of a carbon-fiber reinforced composite rotor blade, manufactured near-net-shape using tape-sandwich injection molding.

In the next step, the core material made of a short-fiber 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 realized 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 molding 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 mold 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 will demonstrate the process live on a tie-bar-less ENGEL victory 120 injection molding 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.

Tie-bar-less ENGEL victory 120 injection molding machine equipped with an easix six-axis robot.

Automated handling in the mold area allows precise process steps directly in the injection mold.

NeoBlade: Interdisciplinary research project across entire value chain

NeoBlade was designed as an interdisciplinary research project spanning the entire value chain. Project partners include ALPEX Technologies, the Energy Institute at JKU Linz, FACC Operations, Plastic Innovation and TU Wien (Aircraft Systems Research Group).

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.

The project evaluated different thermoplastic systems – from high-temperature-resistant materials to cost-efficient alternatives. Compounds with recycled carbon fibers were also used.

Scalable from rotor blades to high-voltage battery covers

Alongside the rotor blade, ENGEL will present another exhibit at JEC based on the thermoplastic tape-sandwich injection molding technology: a high-voltage battery cover made of flame-retardant thermoplastic, measuring 1.3 x 1.8 meters.

The component was named a finalist for the JEC World Innovation Awards 2026 and underlines the scalability of the process – from rotor blades around 30 centimeters long to large-format structural components.

The battery cover combines low weight, high stiffness and full recyclability. Features such as spacers or fastening points can be integrated directly in the process.