E-PROPS ASCALON : Carbon-Titanium Propellers for Direct-Drive Engines

ASCALON : GROUND ADJUSTABLE PITCH PROPELLERS

Multi-objective optimization for high aerodynamic efficiency, minimal weight, superior strength and noise reduction

✗  Range of 2- & 3-blade propellers, ground adjustable pitch, Carbon with Titanium leading edge protection
✗  For tractor aircraft only (for pusher configuration, models under development)
✗  Innovative blade profiles

✗  For direct-drive engines from 80 to 270 hp:
      - 4 cylinder : up to 210 hp
      - 4 cylinder : up to 270 hp
✗  The first range is optimized for Lycoming & Continental engines.
✗  Propellers for Jabiru 2.2 and 3.3, Volkswagen and derivatives, UL Power, D-Motor, etc.: to be followed

✗  Diameters : from 140 cm to 210 cm / 55 inch to 82.7 inch
✗  2-blade weight = 6 kg / 13.3 lb
✗  3-blade weight = 7 kg / 15.5 lb

✗  Max RPM = 3.300
✗  Moment of Inertia : 6000 kg.cm² (for models diameter 190 cm) / Same MOI as wooden propellers for the same engines

✗  Propellers in VHR Carbon [Very High Resistance = Très Haute Résistance] with Titanium leading edge protection
✗  Very strong : 100% carbon, very high fibers ratio, RTM Manufacturing
✗  No cyclic loading on aluminium components = no cracks

100% carbon hub: extremely high strength, no mix of materials and no cracks
Adapted profiles and strings: multi-objective optimization
100% carbon blades + titanium leading edge protection

✗  Carbon Spinners : diameters from 260 mm to 380 mm
✗  Integrated carbon spacers: lengths from 15 mm to 230 mm, every 5 mm

Comparative data coming soon

Thanks to their ESR EFFECT (Extended Speed Range), ASCALON propellers have strong thrust at all engine RPM.

Initial noise measurements show promising results.
A noise reduction of 4 dB(A) was measured when comparing ASCALON to a standard propeller on an aircraft equipped with an exhaust silencer.

The ASCALON range complies with ASTM F2506-13, with a TBO of 2000 hours.
Work is currently underway to obtain EASA CS-P and FAA 14 CFR PART 35 certification for this range.
See page E-PROPS CERTIFICATIONS.

Click on the image to get the PDF file:

DATA SHEET ASCALON

No release date or price yet... coming soon !
We understand — and share — your impatience.
Launching a new range that is significantly more effective in every way than what is currently available on the market inevitably takes time.
Be sure that we are doing everything we can to industrialize, test, and then market this range as soon as possible, in complete safety.

To launch this new range, the E-Props design office developed the LUKY SOFTWARE.
This software uses a carrier line model for execution speed, allowing the exploration of possible propeller designs using an evolutionary (metaheuristic) algorithm, in order to automate the search for propeller solutions (mechanical and aerodynamic design) to a given problem.
This required thousands of hours of coding by highly skilled and specialized engineers. This software is an exceptional advance in the development of new-generation propellers.
Of course, all the parameters must then be checked in flight, which we do using a Data Acquisition System called ELIAS.
This is a complex system of different types of sensors, electronic cards, and strain gauges integrated into the propeller hub, the blade feet, and various strategic locations on the aircraft. During the flight, thousands of measurements are sent in real time to the ground by telemetry, as well as to a display that allows the pilot to refine his piloting according to the parameters requested and obtained. The results obtained are more accurate and realistic than wind tunnel or static bench tests, and they are obtained in a very short time (the duration of the flight). To obtain the same amount of data, years of wind tunnel testing would be required. Furthermore, nothing can replace actual flight conditions. The data is then integrated into the LUKY software.

This set of testing and analysis tools (aircraft and engine + DAU ELIAS + LUKY software) provides invaluable assistance to engineers in the E-PROPS design office.

The design office team acquired several engines to dismantle and analyze the essential parts for the propellers.
See here : Engine study & simulation at E-Props design office
E-Props also purchased an aircraft: PENA Bilouis equipped with a Lycoming O-360 180hp engine.

Ascalon 2-blade full Carbon Titanium, diameter 193 cm, weight 6 kg, on PENA Bilouis Lycoming O-360 180 hp

The E-Props test team in front of the PENA Bilouis Lycoming O-360 180hp aircraft
From left to right, Himaé (test engineer), Jérémie (designer), Samy (test driver), Yoann (test technician)

Return from a test flight: Pilot Samy, Engineer Himaé

ASCALON propeller for Lycoming O-360 180hp engine, side view, with ELIAS test data recording system

Louis Pena is a legendary figure in French aerobatics — a three-time national champion and test pilot for the famous Mudry Cap series. After years of flying and fine-tuning prototypes designed by others, he decided to channel his experience and passion into creating his own line of aerobatic aircraft, specially designed for homebuilders. His goal: to make high-performance aerobatic flying accessible to all, using construction methods within everyone’s reach.
His first creation was the Capena, a single-seat competition aircraft. Exceptionally light and strong, the Capena delivers an outstanding power-to-weight ratio, giving it truly impressive climb performance and agility in the sky.
Building on that success, Louis designed the Bilouis — a two-seat evolution of the Capena. With a larger wingspan and room for engines up to 200 hp, the Bilouis combines robustness, grace, and versatility. Its structure easily handles first- and second-level aerobatic maneuvers, while its tandem seating and classic taildragger configuration give it the sleek profile of a warbird. Available in both fixed and retractable landing gear versions, it’s not only a capable aerobatic performer but also a fantastic touring aircraft.


At E-Props, we were fortunate enough to discover a beautifully crafted Bilouis, built with remarkable attention to detail. It perfectly matches our requirements for propeller flight testing: a Lycoming O-360 180 hp engine — one of the most demanding engines for propellers — and a high VNE of 370 km/h (200 kt), giving us an ideal and generous speed range for in-flight experimentation.