STTR Phase I: Development of an Additively-Manufactured, Non-Toxic, Advanced Storable Hybrid Rocket Propulsion System

Onyx Aerospace, Inc., Huntsville AL

Investigators

Abstract

The broader impact/commercial potential of this Small Business Technology Transfer (STTR) Phase I project seeks to make orbital maneuvers affordable for large and small CubeSat operators. The proposed technology seeks to supply the market with an affordable, “green”, reliable, and easy to integrate modular propulsion system. Minimal integration requirements will allow CubeSat operators to focus on mission objectives and payload first, instead of the propulsion system integration. Today, integrating a propulsion system requires significant accommodations for thermal, electrical, and volume requirements and hazardous propellants limit available launch service. Both of these factors contribute to increasing cost and lenthening schedules. The goal of this project is to make advanced maneuvers, interplanetary trajectories, rapid end of life disposal, and accurate course corrections accessible capabilities for CubeSats. Accessible propulsion may also reduce orbital congestion as fewer maneuverable satellites can equal the capability of many statically-positioned satellites. CubeSats have already enabled rapid deployment of capabilities including low latency communication relays, defense purposes, and scientific research ranging from fundamental physics experiments to Earth observation. The proposed technology seeks to enhance CubeSat capabilities, opening new industries and discoveries for the next great generation of scientists, engineers, and entrepreneurs. This Small Business Technology Transfer (STTR) Phase I project seeks to develop the technology and produce a prototype spaceflight-ready design for a commercially-available, chemical-hybrid propulsion system. Conventional hybrid systems have shown significant downsides due to complex manufacturing, single use and/or toxic ignition systems, and low fuel regression rates. This technology seeks to solve these issues by utilizing a 3-D printed thermoplastic as the base fuel, which has electrical properties that allow for repeatable, rapid, and low power ignition. Some potential propellant combinations have a high theoretical performance, but are incompatible with the ignition method, have a low fuel regression rate, or are difficult to manufacture. After testing propellant combinations for compatibility with the ignition system, the system performance will be simulated. The performance data will be used to evaluate and design a prototype propulsion module. The fuel will be exposed to a simulated space environment and a lab weight scale test will be performed to verify the simulation results. The proposed research plan will identify the best option to produce a competitive and reliable integrated CubeSat propulsion system, with a test campaign constructed to provide confidence that a prototype system will perform as designed. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.