Development of a proof-of-concept space propulsion system for nano-satellite applications using additive manufacturing

In this project, Additive Manufacturing techniques was used to develop a proof-of-concept space propulsion system for nanosatellite applications. The main propulsion unit is made up of a metallic structural housing that is additively manufactured using aluminium powder (AlSi10Mg) on the EOS M290 machine. This housing serves as the reservoir that stores nitrogen gas as the propellant, and other components of the propellant system are assembled into it. The novel feature of the housing is that the propellant feed lines are integrated into the structure. This eliminated welds and joints typically found in conventional propellant storage tank, thereby minimizing leakage whilst simplifying assembly and integration. At the same time, the housing was designed using Design for AM techniques, and this made it possible to increase propellant storage capacity by minimizing support structures. The miniature propulsion nozzle, a key component of the propulsion system, was produced using micro-milling techniques to produce a full 3D converging-diverging profile. A secondary objective of the project was to validate this unique approach by conducting in-space validation experiments to determine the viability of AM in the development of space propulsion applications. Work is currently on-going in the assembly and integration of the proof-of-concept propulsion payload into a 1U Cubesat, where it will serve as the primary payload. This Cubesat mission features a secondary payload which is a commercial off-the-shelf imaging sensor with M12 ruggedized lens that will be tasked with space imaging applications. The current plan is to launch the Cubesat from the International Space Station using the J-SSOD module. The project was carried out by a multi-disciplinary staff/student team comprising faculty members with domain expertise in aerospace, additive manufacturing, avionics/electronics, advanced machining, quality assurance and mechanical testing. The faculty members were responsible for the design, development, and integration of the proof-of-concept propulsion and imaging payloads. The project also provided valuable opportunities for our students to gain hands-on experience in space and satellite engineering. The students hail from the diplomas in aerospace, aviation systems and advanced & digital manufacturing. They were co-located within the Assembly, Integration and Testing lab which features a class 10,000 clean booth. The students supported Cubesat and payload development and integration as well as mechanical testing.