A team of researchers at MIT has successfully developed and demonstrated the first fully 3D-printed electrospray engine, a breakthrough that could revolutionize CubeSat propulsion and space research.
Researchers have demonstrated the first fully 3D-printed, droplet-emitting electrospray engine . This low-cost device can be fabricated more quickly than traditional thrusters, potentially even on board a spacecraft, and could enable CubeSats to perform precise, in-orbit maneuvers, aiding space research projects. An electrospray engine works by applying an electric field to a conductive liquid, generating a high-speed jet of tiny droplets that can propel a spacecraft.
These miniature engines are ideal for small satellites called CubeSats, often used in academic research. Since electrospray engines utilize propellant more efficiently than powerful chemical rockets used on launchpads, they are better suited for precise, in-orbit maneuvers.However, traditional multiplexed electrospray thrusters are typically made via expensive and time-consuming semiconductor cleanroom fabrication, limiting their accessibility and applications. To overcome these barriers, MIT engineers have developed a fully 3D-printed electrospray engine using commercially accessible 3D printing materials and techniques. This device can be produced rapidly at a fraction of the cost of traditional thrusters and could even be manufactured entirely in orbit as 3D printing is compatible with in-space manufacturing. The researchers achieved this by developing a modular process that combines two different vat photopolymerization (VPP) printing methods. VPP involves shining light onto a photosensitive resin, which solidifies to form 3D structures with smooth, high-resolution features. Two-photon printing, a specific VPP method, utilizes a highly focused laser beam to solidify resin in a precisely defined area, building 3D structures one tiny voxel at a time. This enabled the creation of extremely sharp emitter tips and narrow, uniform capillaries for propellant flow. The emitter modules are then fitted into a rectangular manifold block that holds them in place and supplies propellant. The manifold block also integrates the modules with the extractor electrode that triggers propellant ejection from the emitter tips when a suitable voltage is applied. The 3D-printed device generated as much or more thrust than existing droplet-emitting electrospray engines. With this technology, astronauts might quickly print an engine for a satellite without needing to wait for one to be sent up from Earth, democratizing space hardware and enabling more accessible space exploration
3D Printing Electrospray Engine Cubesat Space Exploration Space Research
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