Design and Characterization of Thermoplastic Microthrusters With Nanothermite Intermolecular Composites

Analysis, design and fabrication of 3D printed thermoplastic polymer microthrusters and thruster arrays are presented. We investigate different chamber and nozzle geometry, number of thrusters in arrays, and amount of solid propellants. Synthesis of solid nanoenergetic propellants is researched. We synthesize, test and characterize different nanothermite intermolecular composites. System-level integration, sensing solutions and controlling electronics are studied. Controlling thrusters imply measurements and data acquisition supported by integrated sensors and electronics. The thruster arrays are designed for propulsion, coordination, maneuvering and attitude control of aerial, aerospace, surface and underwater vehicles, including small satellites. The 25-μm-resolution printed thrusters ensure desired capabilities to meet mission-specific requirements with tensile strength up to 55.7 MPa and 2 GPa modulus of elasticity. The ligh-weight thruster arrays do not damaged during propulsion, ensure structural robustness, and, can be reused. The adequate thrust to weight ratio, total impulse, specific impulse, and thrust are ensured by proposed high-energy nanothermite propellants. Experimental measurements of gas generation pressure and velocity for nanoenergetic propellant compositions, as well as thrust are measured and evaluated for the thruster arrays.