RE: Propellers
I would make it out of wood also. Carbon Fibre might be lighter and stronger, but a nice wood prop will be safer and you could CNC it yourself. Do you know the engine that will be used? If so there are many guys here that have flown that engine and can steer you in the right direction. It is also possible on a wood prop to buy one that is bigger than you need and custom cut the tips to your specs. The hardest way would be to CNC a plug , use it to make a mold , than make your own CF version. This would also be the most dangerous way!!! It's no fun when a prop comes apart.
David