Propellers are a key component used in the propulsion of aircrafts, drones, etc. to generate lift or thrust. The propeller design for the use in unmanned aerial vehicles (UAVs) such as drones plays major role in their performance. Based on the requirements for such a typical UAV application, a propeller design has been attempted. The paper deals with designing a propeller based on classical blade element theory and varying the related parameters to achieve satisfactory aerodynamic characteristics, as per the requirements. Sensitivity studies for the design optimisation have been done through CFD analysis, followed by the propeller fabrication through additive manufacturing route and tests in still air with electric motor drive.