September 16, 2025

This Propeller Is 75% Quieter | Tony Bacarella

26 minutes

Propellers may not be the “sexy” part of an aircraft, but the team at Athule Aero is proving they’re the key to unlocking the future of advanced air mobility. In this episode of Hangar X Studios, host John Ramstead sits down with Tony Bacarella, CEO of Athule, to explore how their patented “Double Break” propeller technology is cutting noise by up to 75% and improving efficiency by up to 15%. From custom AI-designed blades for drones to game-changing applications in manned VTOLs, general aviation and even naval uses, Tony explains why the humble propeller is the next big catalyst for aerospace innovation.

️ Episode Highlights

How Athule’s “Double Break” design reshapes the tip of a propeller to slash noise and redistribute thrust

AI/ML-powered design tools that create custom propellers in days, not months

Why noise reduction is critical for urban air mobility adoption

The growing market for U.S.-made drone and propeller components

Opportunities in manned VTOL, hybrid-electric regional aircraft and beyond

⏱️ Key Points with Timestamps

[00:00:00] Welcome to Hangar X Studios & John’s introduction of the vertical economy

[00:01:00] Why propellers are the overlooked “missing link” in EVTOL and drone adoption

[00:02:29] Meet Tony Bacarella – Athule’s breakthrough in propeller technology

[00:04:01] Why propellers are usually an afterthought & how Athule customizes them

[00:04:49] The “aha moment”: validating the tech through an Air Force/AFWERX program

[00:05:52] Explaining Athule’s patented “Double Break” blade and how it deloads the tip

[00:08:36] AI/ML tool redistributes thrust and shapes noise profiles for each aircraft

[00:10:20] Majority of Athule’s work is custom; mass-production also possible

[00:11:17] Noise, FAA rules, and community acceptance for vertiports and urban corridors

[00:12:45] Translating 15% efficiency into range, payload, or speed

[00:13:56] Optimizing for efficiency vs. noise depending on the mission

[00:14:09] Future naval applications & underwater propeller parallels

[00:15:20] Moving from drones to manned advanced air mobility—Athule’s “hockey stick” market

[00:16:31] Potential to supply U.S.-built props amid reliance on Chinese drone parts

[00:17:04] Designing a custom propeller in days using additive manufacturing & CFD

[00:19:30] High-level view of classified military projects

[00:20:28] ISR missions & benefits of quieter propellers for warfighters

[00:20:43] Collaboration with Delta Black Aerospace on the Raider 330

[00:22:18] More collimated downwash and reduced prop-to-prop interference

[00:23:42] Five-year vision: enabling urban environments & hybrid electric regional aircraft

[00:24:37] Where to learn more: Athule.com

Guest Bio – Tony Bacarella

Tony Bacarella is the CEO of Athule Aero, a company redefining propeller technology for drones, advanced air mobility, and general aviation. Working with co-founders from the Air Force Academy and Baylor University, Tony helped transform patented “Double Break” propeller technology—originally validated through an AFWERX SBIR program—into a scalable business. Under his leadership, Athule has developed AI/ML-driven design tools to deliver quieter, more efficient, custom propellers for applications ranging from ISR military platforms to urban air taxis.

https://www.linkedin.com/in/tony-bacarella-95969411/

About Athule Aero

Athule Aero is an innovative aerospace company specializing in next-generation propeller technology for drones, advanced air mobility, and general aviation. Using its patented “Double Break” blade design and AI-driven engineering tools, Athule creates custom propellers that dramatically reduce noise and improve efficiency. With roots in Air Force–backed research, the company delivers quieter, more efficient solutions for commercial, military, and urban air mobility applications—helping unlock the full potential of next-generation aircraft.

Notable Quotes

“Knocking the cabin noise down by 75% for somebody and giving them 10–15% more range is going to be really significant.” — Tony Bacarella [00:00:00]

“The propeller is actually one of the few places you can impact a vehicle nearly as much as we can.” — Tony Bacarella [00:04:49]

“We deload the tip, eliminate the vortex, and can even shape the noise profile around the airframe.” — Tony Bacarella [00:08:36]

“Advanced air mobility is the hockey stick for the industry in the manned space.” — Tony Bacarella [00:15:20]

“We can deliver a custom propeller in days, not months, using cloud-based AI and additive manufacturing.” — Tony Bacarella [00:17:28]

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By John Ramstead