3D Printed Hybrid Propulsion Solutions for SmallSat Lunar Landing and Sample Return

Completed TRL 5 (started at 5, targeting 7)

Description

This NASA-Utah State University cooperative agreement matured and tested a 3D printed High-Performance Green Hybrid Propulsion (HPGHP) system optimized for SmallSat Lunar landing and Sample and Return missions. This hybrid propulsion solution uses a commonly used injection molding plastic, Acrylonitrile Butadiene Styrene (ABS), as the propellant, which has been shown to have unique electrical characteristics that are essential to the improvement of HPGPH technology. ABS can also be 3D printed to any desired shape and used as elements of the thruster which is desirable when there are varying sized diameters. The propellant type and 3D printing capability allow for high performance, low cost, low toxicity, and versatility. Development started at Utah State University’s Propulsion Research Library nearly a decade ago, followed by a a 10 N prototype flight experiment aboard a sounding rocket launched from NASA Wallops in March 2018, and then was further matured and characterized under this project. Advancing SmallSat propulsion is essential for long term presence beyond Earth orbit, particularly in Lunar environments as that is the first stepping stone to reaching deep space.

Benefits

The application of the propulsion system for SmallSats beyond Earth orbit is a key interest of this technology by virtue of its combination of a common, safe, cheap, and 100% recyclable propellant (ABS) and the ability to 3D-print various shaped-components of the thruster on fast turnaround, allowing for a versatile, safe, and cost-effective propulsion solution. Overall, this technology could have widespread applicability across the commercial space industry beyond SmallSats given its scalability and versatility, from nano-rocket launchers to planetary return surface launch systems. Given the thruster’s performance parameters and ignition reliability, low toxicity of the propellant, and ability to 3D-print to the desired shape, it could also enable new low-cost spacecraft mission profiles in both the Earth domain and in deep space.

Details

Technology area	Entry, Descent, and Landing > Landing > Propulsion Systems for Landing
Program	Small Spacecraft Technology (SST)
Lead organization	Utah State University, Logan, UT
Start date	2020-07-01
End date	2025-09-30

Project contacts

Listed on TechPort itself — the most direct way to ask about this specific project.

Stephen Whitmore
Matthew Harris

How to get involved

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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