Conceptual demonstration of a Lego-like modular fabrication method for an engineering model of a small monopropellant PCB thrusters

Abstract

We present an innovative modular fabrication method for a green monopropellant thruster, employing printed circuit boards (PCB) as fundamental building blocks for rapid and efficient performance optimization. This PCB-based approach offers superior thermal and structural characteristics to conventional MEMS-based microthrusters. Furthermore, it streamlines mass production and facilitates the swift and reliable assembly of thrusters using well-established PCB surface mount technology. In this study, we present a conceptual demonstration of this pioneering materials and fabrication technique, exemplified by the development of a 200 mN thrust monopropellant thruster utilizing 90 wt% hydrogen peroxide. Subsequently, we conduct propulsion experiments and consistently observe identical patterns in pulse mode firing tests, demonstrating the repeatability of the system. The experimental results, including thrust and C* efficiencies, provide substantial evidence for the validity and feasibility of our proposed approach. The modular fabrication method presented in this study exhibits high potential for mass production of small satellite thrusters, effectively addressing the expanding thruster market.