Additive Manufacturing ASCENT Propulsion Catalyst Beds

Project Objective  

Sierra Space is developing and testing additive manufactured thruster catalyst beds for Advanced Spacecraft Energetic Non-Toxic Propellant (ASCENT) thrusters which can drive down cost of integrated thrusters while also improving thermal management performance of these complex systems.

Project Description 

For this effort, Sierra Space is seeking to expand the marked in small satellite thrusters which use domestic non-toxic propellants (e.g., ASCENT). Sierra is focusing on addressing the catalyst materials in these monopropellant thrusters by implying additive manufacturing approaches to optimal materials and subsequently testing these materials in sub-thruster scale laboratory experiments to determine reaction rates. This work is planned for application in thruster component development and subsequent thruster testing.

Project Results and Conclusions 

Thus far, Sierra has successfully manufactured both an additive hydrazine control catalyst and has subsequently demonstrated successful and improved combustion on ASCENT catalyst samples. Sierra is still working towards full up catalyst testing at a near future date.

Sierra is expanding the envelope in terms of advanced thermal management and improved catalytic ignition performance in small spacecraft thrusters which use advanced/non-toxic propellants. 

This is early/mid-stage (TRL 4) — 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.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.