Our official Army TASC training aid CH-47 model at work had broken "blades" (the plexiglass discs). I modeled these to be printed flat and the spindle can be screwed or glued to the blade hub. They were originally a little more accurate to life, but I had to beef up the hubs to make them stronger.
I printed in ABS and they are plenty strong!
They are scaled for the Army training aid and can be printed on a 350mm bed at this scaling.
The author marked this model as their own original creation.