The ALBACOPTER® project, led by the Fraunhofer Institutes, is an experimental research initiative focused on urban air mobility. The goal is to develop an airborne platform that combines the vertical takeoff and landing (VTOL) capabilities of multicopters with the aerodynamic efficiency of glider-like flight. By exploring this hybrid approach, the project aims to create safer, more efficient, and sustainable solutions for future aerial transportation.

The initiative brings together expertise from multiple Fraunhofer Institutes, covering areas such as materials science, propulsion technology, automation, and flight control. The research spans different prototype scales, allowing for progressive testing and validation of key technologies.

Helix’s Contribution: Advanced Propeller Manufacturing
For this project, Helix designed and manufactured the propeller used in the ALBACOPTER®. To meet the demands of lightweight construction and high performance, we employed High Pressure Resin Transfer Molding (HP-RTM). This production method enables the creation of stronger, lighter propellers while significantly improving manufacturing efficiency compared to traditional carbon fiber layering.

After production, we conducted extensive testing at our facilities in Aachen to verify the propeller’s structural integrity and aerodynamic performance. These tests ensured that the propeller met the requirements for the ALBACOPTER® platform before further integration steps took place.

Sensor Technology and Future Applications
Following the propeller tests, the Fraunhofer team integrated sensor technology directly into the blades. These sensors provide real-time data on deformation, vibrations, and temperature, allowing for improved monitoring and predictive maintenance. The ability to collect in-flight data at this level could enhance safety, efficiency, and longevity for future aerial mobility applications.

Helix is proud to be part of this forward-thinking project, contributing our expertise in high-performance propeller design and manufacturing.

Read more about the ALBACOPTER® at the Frauenhofer Institute’s website.

Read the original press release