Development of A Modular, Cold Gas Propulsion System for Small Satellite Applications

TLDR

Additive manufacturing of propulsion components is especially useful for small satellites. The system is 3D‑printed using stereolithography, allowing complex thruster geometry, and operates by serially releasing saturated liquid propellant through three valves into a built‑in converging‑diverging nozzle. Tests show the 3D‑printed system achieves 65–89 s specific impulse, 110–150 mN thrust, a total mass under 400 g, and delivers at least 10 m/s delta‑v.

Abstract

A novel cold gas propulsion system for small satellites has been developed at the University of Texas at Austin’s Satellite Design Lab. The concept behind the propulsion system is to additively manufacture the main thruster module by means of the stereolithography process. In this manner, intricate features can be created and complex volumes can be used. This method is especially useful for small satellites. The propulsion system operates by releas ing a saturated liquid propellant serially through three valves and a built-in converging-diverging nozzle. Through extensive tests, the propulsion system was measured with a specific impulse that ranged from 65 seconds at 24oC to over 89 seconds at 85oC . The measured thrust force provided by the propulsion system ranged from 110 mN at 24oC to over 150 mN at 85oC. A technology demonstration unit has been developed for flight onboard the Uni versity of Texas at Austin’s Bevo-2 satellite. This system will have a total mass under 400 grams, including 90 grams of Dupont 236-fa as propellant. The propulsion system is expected to provide at least 10 m s -1 of delta-v capability, which has been verified through testing.