[...] in this case the problem is clearly caused by deformed props, not the motor axis.
I'm starting to suspect that the motor axis angles actually do have influence on how the props become deformed. It has to do with the way the props mesh when stored with the arms folded.
This diagram shows how the front and rear motors are mounted on different angles. I don't know the actual precise angle, these are just estimates, but the rear motors are noticeably canted outwards, while the front motors are canted rearward.
I've always been cautious to fold the props correctly when storing the Mini in its Fly More case, so I really don't believe I ever jammed them in there improperly. But I nevertheless received the Motor Speed warning on my first flight with the v01.00.05 firmware. I replaced the rear-left blades as instructed and haven't seen the warning again.
However, I did notice this. Previously the left and right prop blades slid neatly together when nested with arms folded. But, the tips of the newly installed fresh blades stand higher than the old ones, and they no longer slide under the other blades. Because of the way the rear motors are canted outwards, the tips of the prop blades stand higher than the opposite motor.
I subsequently also replaced the rear-right blades. They now also point higher than the opposite motor.
With fresh blades installed on both rear motors, you can see the tips of the blades now cross each other. The props can no longer be nested together without forcing one set to bend under the other set.
Storing the Mini for any period of time with the props crossed under each other will eventually cause the blades to permanently deflect. Even when stored "
correctly" within the Fly More case, I still suspect forcing the blades to fold together is what's causing them to take on a permanent deflection.
This might even explain why some people have experienced Uncommanded Descents with brand new Mavic Minis straight out of the box. The Mini is shipped with the arms folded. There's no telling how long they've been stored like that before their first flight.
So how come we're seeing the Motor Speed warnings almost exclusively on the rear motors, and practically never on the front motors?
Well, with the arms folded, the fronts motors on my Mini are almost exactly level with each other, maybe even canted slight
inwards.
I also replaced the front-right blades. These are the fresh blades (below).
And these (below) are still the original front-left blades which have been on the Mini since December.
When folded together, the front blades mesh easily without putting any bending stress on each other.
What do you guys think? Does any of that make sense?
Edit: Correction, I replaced the left-front leaving the right-front blades as the only ones still original.