The vane thickness could be modified slightly but the way it looks is pretty critical to the preformance. I have investigated creating a helical sweep on the base diameter then using that sweep to project to keeping the vanes straight. That didn't work out. What I am looking at now is seeing if I can mold this in 3? parts then assemble it back into an assembly. We currently make some colsed impeller in two parts and sonic weld them back together, this works pretty well. With this I'm not sure yet, I know I'll have to work close with the molder.
thanks