Development of Novel Green Propellant Dual-Mode Thrusters

Project Objective  

Igneon Aerospace (Hyperion) is addressing the relatively limited market availability of low-toxicity thrusters by developing small spacecraft-scale thrusters which can use multiple blends of the the Advanced Space Craft Energetic Non-Toxic (ASCENT) family of ionic liquid propellants.

Project Description 

Igneon Aerospace (formerly Hyperion) aims to develop and demonstrate a new generation of low-toxicity monopropellant thrusters that use ASCENT and its blends (e.g., DM-4) developed by the Air Force Research Laboratory (AFRL). The goal is to provide affordable, high-performance, and both low-cost and relatively easily manufacturable thruster products for small spacecraft.

Goals of this project include:

• Developing and hot-fire testing two DM-4 thruster sizes (one 0.2 Newton(N) thruster and one 22-N thruster);
• Addressing current shortcomings in low-toxicity propellant thruster development (eliminating reliance on expensive refractory metals which emit higher combustion temperatures);
• Demonstrating accelerated thruster development cycles and shorter production times for low-toxicity thrusters; and
• Enabling dual-mode propulsion systems (this is a long-term goal).

Project Results and Conclusions 
 

With FY25, Igneon has successfully designed both the 0.2-N and the 22-N ASCENT thruster per the Cooperative Agreement Notice (CAN) with NASA MSFC. The 0.2-N thruster components were successfully manufactured, assembled, and subsequently performed acceptance testing with ASCENT, estimating a move from TRL-4 to TRL-6. Hyperion has recently overcome challenges with acquisition of the DM-4 propellant blend as well as longer than anticipated lead times for the manufacturing of the 22-N thruster. This has led to the need for an extension of this effort. Igneon hopes to complete a 0.2-N thruster test campaign with DM-4 as well as an eventual assembly and test of the 22-N thruster.

Project benefits include increasing thruster options for small spacecraft which use non-toxic propellants in small and larger thruster classes. Additional benefits include reduction in cost and overall lead time of manufacturing small satellite non-toxic thrusters. Also, the thrusters produced by Igneon will demonstrate use for various blends of ASCENT; this will allow for a wider range of applications for dual-mode (chemical and electrospray) propulsion systems and mission classes.

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