3D Printed Miniaturized Micro Thrusters for Cubesat Applications

Small satellite applications are rapidly developing in the New Space business, primarily due to the advancements in electronics and miniaturization. Small satellites have several advantages, including a shorter development time, reduced costs, simplified maintenance, and mass reduction. As a result, miniature satellites are currently being investigated for a wide range of space-based applications. Moreover, advancements in formation flying have significantly enhanced mission value in recent years, thanks to the adaptability and reconfigurability of satellite formations. This flexibility enables the incremental addition of new components or updates to existing structures, providing inherent versatility, multi-mission capabilities, design flexibility, and mission enhancement. Once launched into Earth’s orbit, the satellite is subjected to a number of perturbations, and must operate within the designated orbit or formation while coordinating with one another to achieve mission objectives. Miniaturized propulsion technologies, including as chemical and electrical propulsion, play a critical role in achieving mission designs and maintaining satellite formation flying in this environment. In this article, the feasibility of a 3D printed solid propellant micro rocket thrusters, fully integrated in an opposing array is examined both numerically and experimentally. The key advantage of this system lays in the possibility of firing the rocket individually or with others, depending on thrust requirements. A micro-igniter is used to start the combustion of the solid propellant. Theoretical, and experimental results demonstrated that these microthrusters, made of nylon, have good mechanical and thermal resistance while achieving high-performance levels. Additionally, this approach offers reduced costs and shorter production and manufacturing timelines, making it a promising solution for future space missions.