Understanding Differences between Skydio X10 REV 1 and REV 2 Propellers

We’ve updated the design of our Skydio X10 propellers to enhance durability and reliability. This new REV 2 propeller design addresses an accelerated propeller hub wear issue seen with our previous REV 1 design per NTO: Skydio X10 Accelerated Propeller Hub Wear. Ultimately, our REV 1 propellers did not meet our original performance specifications under these high-stress flight conditions: 

• Sustained flight airspeed above 33 mph (53 km/h) 
• Aggressive or max throttle, pitch, and yaw 
• Flights conducted in high wind or gust conditions

REV 2 Propeller Design Improvements

After a comprehensive investigation, we found that the aerospace grade aluminum and stainless steel materials used in our REV 1 propeller design contributed significantly to accelerated prop hub wear. The updated design provides additional support for the hub and dramatically improves the lifespan of the propeller assembly.

Our REV 2 propeller design features two primary changes:

• Materials: We’ve shifted to using low-friction plastic as we found that this was most capable of handling high aerodynamic loads at the interface of propeller hub and the motor shaft
• Stabilizing Hoop: Added to reduce strain on the quick-release attachment point and improve structural integrity under high-stress/high-speed flight conditions

We’ve done extensive validation and testing with this new design, to confirm that REV 2 propellers show an order of magnitude improvement over REV 1 props in high-stress/high-speed flight conditions.

Maintenance Guidelines

[note] Propellers are consumable items and should be planned for and replaced as part of a regular maintenance schedule when they reach the end of their usable life. To purchase new propellers, work with your Skydio account team. [/note]

REV 2 Propellers

Perform a routine preflight inspection to ensure your propellers are in good working condition. 

• For optimal performance, Skydio recommends replacing your propellers at 250 hours of flight time or whenever you notice any damage. 
• In high-stress flight conditions with multiple attachments, replace your propellers at 100 hours of flight time. 

It is important to update the propeller type in Cloud once Rev 2 props are received to get proper time-based alerting.

[warning] Propellers with hairline cracks or large breaks, chops, or bends should be replaced immediately. Do not fly with Skydio X10 with propellers that are not in good condition as serious bodily harm or injury may occur. [/warning]

REV 1 Propellers

All vehicles that were shipped with REV 1 propellers will be getting REV 2 propeller replacements by November 2025. While we work to replace all REV 1 propellers, if you are flying vehicles with REV 1 propellers in your fleet please continue to follow the safety and maintenance guidance below:

REV 1 Propeller Inspection Intervals

• Skydio recommends vehicles accumulating flight hours primarily via high-stress profile conditions (described above) undergo a short visual propeller hub inspection every 5 flight hours.
• If not flying in high-stress profile conditions, out of an abundance of caution, Skydio recommends all operators perform the propeller hub inspection every 50 flight hours.
• Immediately replace the propellers if accelerated wear conditions are found.

REV 1 Propeller Inspection procedure

The inspection procedure involves observing the degree of movement in the propeller hub and the motor shaft.

Step 1 - Place Skydio X10 on a stable, flat surface with adequate lighting to familiarize yourself with the propeller assembly

Step 2 - Grasp the motor between your index finger and thumb with one hand, then grasp the propeller hub with your other hand

Step 3 - Apply firm opposite torsion between the propeller hub and the motor in both directions without pressing downward

Step 4 - Look and feel for movement of the motor shaft compared to the pocket it rests in within the propeller hub

Step 6 - Repeat the inspection process on the remaining three propeller hubs

• If you observe accelerated pocket movement in any propeller hubs, replace all four propeller hubs
• If in doubt, contact Skydio Support and provide close-up photos of the propeller hub assembly, or arrange for no-charge replacement propeller sets to be sent to you

Step 7 - When replacing propellers, Skydio recommends inspecting the motor shaft spring. 

How to inspect X10 Propeller Springs

The X10 propeller springs keep the propeller in place and allows for easy installation and removal of the propeller. The springs can get damaged after high flight hours or with Revision 1 propellers. 

Inspect all four propeller springs. If all conditions are true, the drone propeller springs must be replaced. Reach out to Skydio Support for further assistance: 

• Spring is damaged or broken in pieces
• The motor spins freely while hand spinning'

To request spare parts for propeller spring repairs, contact the Skydio Support team. 

[note] If the motor does not spin freely, contact the Skydio Support team for next steps as the drone will need to come back to Skydio for repair. [/note]

Skydio Inc., A0590