Hi.
My aproach is to choose a standard blade form (design of Y. Yatsenko) and zoom it bigger or smaller in 1/4" increments, and then have them cut with a CNC machine. Standard pitch is about 6" which I can easily manipulate +o/-1" by heating & tweaking, with 1/8" steps.
Some may think it's lots of work but at least I have a good control over variables.
Just remember, gyrorcopical effect increases exponentially as you increase diameter, and linearry with prop weight. So, usually less diameter and more blades is better.
But bigger diameter helps to make round maneuvres round. And less diameter helps to penetrate into wind. Allways aim to smallest diameter that the plane is happy with.
L