Anton
To build this, you'll need a 3D printer, some ABS plastic, acetone (for aerodynamic glossy finish treatment), a large glass bowl (acetone vapor chamber), and about two hours. To test these blades, you'll need a quadcopter which uses four or six hexagonal (6x2.5mm circumference) propeller inputs. The list of recommended settings for the 3D printer software, as well as other instructions can be found on Thingiverse here: http://www.thingiverse.com/thing:1060181
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3D-Printable Propeller
Using a RepRap 3D printer to manufacture functional propellers for UAVs.
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Swaleh Owais
Eric Cantrell
RenierM
Where I used to work we would print our props and motor housing for R&D. I havn't tried non-comercial printers, but I think it is a great way to rapidly prototype a design.