Ok,
Here is a YouTube video I posted showing how I am making the blades. I should have showed my settings more. I am in the mm unit system and have a mesh angle of 1.0 degrees. I have found these two things to allow the creation of the blades without issues.
Anthony
Edit; This video has since been updated to match the latest version of PROP_DESIGN. See a later post, for the current link.
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