Additive Manufacturing and Performance Measurement of an Electroplated Electrospray Propulsion System

Microsatellites have become increasingly capable and popular in recent years, driving down the cost to access space. However, propulsion systems for these microsatellites have lagged in development. As a result, many are being launched without propulsion systems needed for orbital maintenance, interplanetary travel, and other critical operations. Our research details the development of an additively manufactured electrospray propulsion system that fits the size and budget constraints of modern microsatellites. We fabricated electrospray thrusters using stereolithography 3D printers, a cost-effective alternative to the MEMS manufacturing methods typically used. These thrusters were found to have an average tip diameter—a marker of thruster efficiency—of approximately 25 𝜇m, a fivefold improvement on additively manufactured electrospray thrusters previously reported in the literature. We also document the successful copper electroplating of these 3D-printed thrusters, which may lead to improved thrust and efficiency. Preliminary thrust measurements will also be presented, comparing the performance of our thrusters to typical MEMS-manufactured ones. These findings confirm both the feasibility and potential advantages of additively manufacturing an electrospray propulsion system.