Engineers at MIT have created a fully 3D-printed engine that could change the way small satellites move in space.
This new electrospray engine is cheaper and faster to produce than traditional ones, making space exploration more accessible.
What is an electrospray engine?
An electrospray engine works by applying an electric field to a special liquid, creating tiny, high-speed droplets that generate thrust.
This type of engine is perfect for small satellites, called CubeSats, which are often used for research.
Unlike large chemical rockets that burn fuel quickly, electrospray engines use their propellant much more efficiently.
They provide gentle but precise thrust, which is ideal for small movements in space.
However, making these engines has traditionally been expensive and complicated, requiring advanced cleanroom facilities.
To make space technology more affordable, MIT engineers have designed an electrospray engine that can be fully 3D-printed.
This means it can be produced quickly and at a much lower cost. Since 3D printing can be done in space, astronauts could even print these engines onboard instead of waiting for shipments from Earth.
The new thruster consists of 32 small nozzles, called emitters, that work together to spray propellant.
It is made using two different 3D printing techniques to ensure all parts fit perfectly.
One method, called two-photon printing, is used to create the extremely sharp emitter tips needed for efficient thrust. Another method, digital light processing, is used to build the larger casing that holds everything together.
A key challenge was making sure the printing materials wouldn’t react badly with the propellant. The team also found a way to tightly assemble the parts without leaks or misalignments.
The 3D-printed engine performed better than existing electrospray thrusters, generating strong and stable thrust. The researchers also discovered that adjusting the engine’s voltage was an easier way to control thrust than using complex pressure systems. This makes the engine lighter, cheaper, and more efficient.
The team plans to keep improving their design by increasing the number of emitters and making the engine even more powerful. In the future, they hope to test a CubeSat using a fully 3D-printed electrospray engine.
“We want to make space technology accessible to more people,” says MIT researcher Luis Fernando Velásquez-García. “With this new approach, building high-performance engines is faster, easier, and more affordable.”
This innovation could help more universities, companies, and even space agencies launch small satellites, opening new opportunities for space research and exploration.
