JCU scientists test 3D printed rocket fuel for low-Earth orbit satellites

China3D printingOn August 2nd, scientists at James Cook University (JCU) in Australia used3D printingThe fuel particles power the hybrid rocket engine.According to foreign media reports, theFuel isDeveloped because of the increase in rocket launches, partly because of the increase in private space exploration companies, new processes and accessible plastics are considered necessary to help meet the energy needs of this propellant.
Dr. Elsa Antunes, a lecturer in mechanical engineering at JCU, led the project research. According to Dr. Actunes, “There are many new investors and the demand for satellites is increasing.
3D printing, Which means that designers have been able to make more complex geometries for rockets, and also opened up the possibility of using new fuels to power them. “

Small fuel pellets, from left to right: ABS, PLA, PETG, PP, ASA, nylon and AL. The photo is from JCU.

3D printingAnd rocket science

Use ABS, PLA, PP, ASA, PTEG and AL (PLA with aluminum particles) to manufacture3D printingThe initial size of the round pellets is 100mm long, 20mm diameter and 6mm straight circular combustion port. A laboratory with sensors and a rocket engine test bench have also been developed to conduct small-scale static ignition tests to explore the performance of these FFF/FDM materials.
“We hope to explore the use of commercially available3D printingMaterial feasibility. We know that ordinary plastic ABS has shown promise, so we decided to test other compounds,” Dr. Antunes added.

Combustion port comparison, from left to right: ABS, PLA, PP, ASA, PTEG and AL. The photo is from JCU.

The test causes two fuel particles of each material to burn in the motor for three seconds. The grains are then dissected for further analysis. According to reports, there are significant differences between high-performance materials and ordinary plastics. 3D printingThe nylon particles cannot be removed from the motor housing without obvious damage, so it cannot be inspected.

Dr. Antunes continued, “We are disappointed with PLA and AL, we think this is mainly due to the size, shape and surface area of the aluminum particles-but this is another thing we can explore in the near future while taking advantage of modern manufacturing technologies. .”

The cross section of each different small-scale fuel particle, from left to right: ABS, PLA, PP, ASA, PTEG and AL. The photo is from JCU.

3D printingNew rocket fuel

The study showed that despite the poor performance of AL particles, they still have potential. Therefore, it is recommended to use aluminum particles of different sizes, shapes and surface areas for further testing. This experiment is the first step to achieve a larger-scale engine ignition movement, and it is also the best available fuel for low-Earth orbit equipment.
With the help of3D printingWaiting for new manufacturing technology, we can do things that were simply not possible in the past.
Prior to this research, in 2017, Rocket Crafters began to develop and commercialize the hybrid rocket engine (HRE) technology invented by Ronald Jones. Ronald Jones was the chief technical expert and the Florida company’s Co-founder.

3D printingA patent for rocket fuel technology for the production of raw materials and printing rocket fuel from a mixture of thermoplastic and high-energy nano-scale aluminum particles. The rocket fuel uses nano-sized particles of pure aluminum, which has high reactivity.
Made of different materials3D printingSmall-scale static ignition test of mixed rocket fuel particles.