Hat tip to FlightSchoolList.com for finding and posting two interesting videos about how aircraft propellers are made. In the first video, hiVelocity Media traveled to Piqua (Ohio) to visit Hartzell Propeller – which began as a lumberyard in the late 1800s and made its first propeller blade back in 1917. Hartzell Propeller’s first aircraft propellers were made of wood that was glued and laminated together but today they are made out of either forged aluminum alloy or composite (Kevlar or carbon) – the later being lightweight, strong and will literally last forever.
Meanwhile, the second five minute video comes from the Discovery / Science Channel’s "How It’s Made" Airplane Propellers episode:
Finally, "How It’s Made" also has the following video about how traditional wood aircraft propellers are made: