Additive Manufacturing at the Nanoscale for Microfluidic Space Applications

Two-photon polymerization (TPP) is an additive manufacturing technique using femtosecond lasers in the near infrared range to excite initiating species and induce polymerization at the laser's focal point. This method creates nanoscale arbitrary 3D structures with sub-100 nm achievable resolution and the ability to alter the chemical and mechanical material properties. Applications of this technology range from optical devices to tissue engineering and microfluidics. I desire to investigate the application of TPP to space systems. A reliable, repeatable manufacturing method at the established high-speeds could, for example, be utilized for manufacturing crystals or biomaterials in-space, producing nanodevices and sensors leading to spacecraft mass savings, and implementing microneedles in spacesuits for emergency drug delivery. To demonstrate this technology, I propose the additive manufacturing of electrospray emitters, an electric propulsion technology that electrostatically extracts and accelerates ions or droplets to produce thrust. Life-limiting mechanisms of electrosprays involve the propellant flow path at each individual emitter, exhibited through shorting incidences from fluid accumulation at the emitter's base and emission non-uniformities originating in manufacturing difficulties. Achieving greater accuracy in emitter features would mitigate failures and improve performance. To accomplish this, I propose: (i) the numerical simulation of favorable emitter structures, (ii) emitter fabrication in individual and array configurations to demonstrate TPP manufacturing capabilities, and (iii) experimental testing to characterize the resulting electrospray's performance. Validating this technology and producing high accuracy electrospray thrusters could lead to improvements in propulsion on small satellites, like finer pointing accuracy and orbital maneuvering capabilities. Scaling these thruster arrays reveals applications to larger missions, to expand the conduction of space research further into space than ever before. With rapid prototyping capability, repeatedly demonstrated high resolution, and a growing commercial market, two-photon polymerization is a promising technology that could revolutionize electric thruster manufacturing and presents substantial opportunity for space systems applications.

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