Comparative Efficiency Measurement of UAV Propellers Using a Microcontroller-Based Test Bench

Optimizing small-scale electric propulsion systems is essential for improving Unmanned Aerial Vehicle (UAV) performance. However, the complexity and specialized nature of commercial test equipment remain a significant barrier. This paper details the design, fabrication, and validation of an accessible, microcontroller-based instrument capable of comprehensive performance characterization. The system integrates an ESP32 microcontroller to simultaneously measure mechanical thrust, electrical power consumption, and exit airflow velocity. To demonstrate its analytical capabilities, the instrument was used to conduct a comparative study on three 10×5-inch propellers fabricated using different methods: commercial injection molding, silicone mold casting, and 3D printing. The results revealed significant performance variations, with the developed instrument successfully measuring total propulsive efficiencies ranging from 18% to a peak of 30%. The commercial propeller was identified as the most efficient. This study validates the developed test bench as an effective and accessible tool for detailed analysis and the optimization of electric propulsion systems.