Once a propeller is designed, the geometry must be produced One of the most common manufacturing methods for modern propellers is to produce a thickened casting so that the final geometry can be machined through grinding or milling. To ensure the casting will encompass the final geometry, several geometric corrections must be applied to account for the sand casting manufacturing process. The corrections provide compensation due to solidification shrinkage, solid shrinkage, machining tolerance, and distortion during cooling. The objective of this paper is to review and understand the mechanisms that result in geometric differences during the casting process. Common correction strategies will be recommended for correcting design geometry for pattern creation. Lastly, an implementation of a generalized correction methodology will be demonstrated using HydroComp PropCad, a commercial design tool for propeller geometries.

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