Consumable Spacecraft Structure with Integrated, 3-D Printed Acrylonitrile Butadiene Styrene (ABS) Thrusters

摘要

The propulsion research laboratory at Utah State University has recently developed a "green" 3-D printed hybrid rocket thruster system with the capability to provide small spacecraft with safe and efficient in-space propulsion. This technology has been adapted to the design of a partially consumable structure where 3D-printed propulsion elements made from Acrylonitrile Butadiene Styrene (ABS) act as both fuel for propulsion and structural support for the spacecraft. The consumable design allows for a significant reduction of the overall dry mass, and offers a potentially significant reduction of launch costs. Using gaseous oxygen and ABS as propellants, ground-based experiments have recorded vacuum specific impulse values greater than 280 seconds. Based on this Isp and available 3U CubeSat volume this system has the projected capability to produce over 90 m/s of AV for a 4 kg spacecraft. Each motor has capability for multiple on-demand restarts with typical ignition energies are less than 3 Joules. Thus, the same system can conceivably be used for orbit raising, station keeping, and deorbiting, among other maneuvers. Hydrostatic and hot-fire testing has been completed on prototype partially-consumable, nickel plated thrusters; demonstrating the viability of this technology. Results from the testing campaign on the prototype designs are presented.