There is a nice tool by M. Hepperle: PropellerScanner (
here at his Software page). All you have to do is photograph or scan a front and side view of a prop. The geometry including the pitch (varying over the radius) is taken from the pictures fairly accurately. It spares you the tedious pitch measurements.
Next step would be entering the geometry data into M. Hepperle's
JavaProp applet and calculate a coefficient table. The tool neglects some aerodynamic effects and may overestimate thrust, for instance. Yet the results are quite useful and far better than values extrapolated from static measurements. Of course, the calculated coefficients are useless for speeds (advance ratios) where there is some blade stall, but the tool indicates blade stall quite reliably. Besides, if a drive with maximum efficiency is required there has to be no blade stall, anyway.
To find the optimum drive for a given task one could use my spreadsheets which I mentioned in
another thread. They use the coefficients calculated in JavaProp and motor data from measurements or specified by the manufacturer.
If there is no way to measure in a wind tunnel this "workflow" is far better and economic than static testing. It doesn't even require having the motors and ESCs, just the props.