A device may include an electrically-operated propellant or energetic gas-generating material, additively manufactured together with electrodes for producing a reaction in the material. The device may also include a casing that is additively manufactured with the other components. The additive manufacturing may be accomplished by extruding or otherwise depositing raw materials for the different components where desired. The electrodes may be made of a conductive polymer material, for example using an electrically-conductive fill in a polymer.

Various implementations of an extinguishable, solid propellant divert system for a flight vehicle are disclosed. Also disclosed are methods for using the divert system to control the flight of a flight vehicle. In one implementation, a divert system includes a hot gas generator pneumatically linked to one or more divert thrusters and an extinguishment valve. The extinguishment valve can be opened to rapidly depressurize the hot gas generator and extinguish the solid propellant burning inside. In another implementation, a method of controlling the trajectory of the flight vehicle includes repeatedly igniting and extinguishing the solid propellant in a hot gas generator and using the hot gas to provide divert thrust for the flight vehicle.

A rocket engine pintle injector with optimized spray pattern and with integrated igniter design for providing construction simplicity, throttleable thrust, stop/start/restart capability, optimized operational combustion, and improved ignition combustion stability. A user can start, throttle, and stop the engine by moving the internal concentric injector sleeve forward and backward to cause the fuel/oxidizer to spray out of the pintle head at different flow rates. The concentric igniter can be deployed so that the hot gasses or spark produced are radially projected into the spray of fuel/oxidizer surrounding the igniter. Once the fuel/oxidizer spray has been ignited, the igniter is stopped and retracted to protect the device from the heat of the combustion chamber and is ready for redeployment and restart of the engine as needed. Thus, a versatile, fully integrated, and scalable device can be used to start, throttle, stop, and restart any size rocket engine during any mission phase from launch to return from space.

A rocket motor has an electrically operated propellant initiator for a propellant grain that includes an electrode arrangement configured to concentrate an electric field at an ignition electrode for igniting an electrically operated propellant. The rocket motor includes a combustion chamber containing at least one propellant grain and an electrically operated propellant initiator operatively coupled to the propellant grain to initiate combustion of the propellant grain. The electrically operated propellant initiator includes the electrically operated propellant and at least one pair of electrodes configured to ignite the electrically operated propellant. The pair of electrodes includes a ground plane electrode and an ignition electrode. When an electrical input is applied to the electrically operated propellant initiator, the electric field is concentrated at the ignition electrode to ignite the electrically operated propellant at the location where the ignition electrode is arranged.

A rocket motor has an electrically operated propellant initiator for a propellant grain that includes an electrode arrangement configured to concentrate an electric field at an ignition electrode for igniting an electrically operated propellant. The rocket motor includes a combustion chamber containing at least one propellant grain and an electrically operated propellant initiator operatively coupled to the propellant grain to initiate combustion of the propellant grain. The electrically operated propellant initiator includes the electrically operated propellant and at least one pair of electrodes configured to ignite the electrically operated propellant. The pair of electrodes includes a ground plane electrode and an ignition electrode. When an electrical input is applied to the electrically operated propellant initiator, the electric field is concentrated at the ignition electrode to ignite the electrically operated propellant at the location where the ignition electrode is arranged.

An ignition safety device (ISD) used in an ignition system of a missile is configured to selectively control the ignition of two or more pulses or stages of a rocket motor propulsion system, based on a flight profile mode selection of a flight velocity mode, in which the missile is configured to travel at an optimized flight velocity, or a flight distance mode, in which the missile is configured to travel an optimized flight distance. The ISD is configured to selectively ignite the pulses or stages substantially simultaneously upon selection of the flight velocity mode, or in a delayed sequential manner upon selection of the flight distance mode. The ISD is also configured to selectively inhibit the delayed sequential ignition of the pulses or stages in the event of incidental ground or water impact of the missile after ignition of the primary pulse or stage.

An ignition safety device (ISD) used in an ignition system of a missile is configured to selectively control the ignition of two or more pulses or stages of a rocket motor propulsion system, based on a flight profile mode selection of a flight velocity mode, in which the missile is configured to travel at an optimized flight velocity, or a flight distance mode, in which the missile is configured to travel an optimized flight distance. The ISD is configured to selectively ignite the pulses or stages substantially simultaneously upon selection of the flight velocity mode, or in a delayed sequential manner upon selection of the flight distance mode. The ISD is also configured to selectively inhibit the delayed sequential ignition of the pulses or stages in the event of incidental ground or water impact of the missile after ignition of the primary pulse or stage.

A multi-pulse propulsion system includes at least one pulse chamber containing at least one propellant for igniting during at least one pulse of the multi-pulse propulsion system, at least one additional pulse chamber containing at least one additional propellant for igniting during at least one additional pulse of the multi-pulse propulsion system, and at least one passive fuzing system configured to initiate the at least one additional pulse. The at least one passive fuzing system includes a sensor and an igniter. The sensor is configured to sense an environmental condition and/or a ballistic condition. The igniter is configured to provide a stimulus that causes ignition of the at least one additional propellant in response to the sensor sensing that the environmental condition and/or the ballistic condition has reached or exceeded one or more threshold values.

The first solid propellant is formed to have a columnar shape so as for a combustion surface to move to a first direction, and to have an end surface exposed to a combustion space. The surface of first solid propellant except for the end surface is covered with a barrier membrane. The position of combustion surface in the first direction is detected by a position sensor device in an always-on measurement or a fixed-point measurement. Based on the detected result, the consumption amount of the first solid propellant is estimated.

A satellite has thrusters that are integral parts of its frame. The frame defines cavities therein where thrusters are located. The thrusters may include an electrically-operated propellant and electrodes to activate combustion in the electrically-operated propellant. The frame may be additively manufactured, and the propellant and/or the electrodes may also be additively manufactured, with the frame and the propellant and/or the electrodes also being manufactured in a single process. In addition the thrusters may have nozzle portions through which combustion gases exit the thrusters. The thrusters may be located at corners and/or along edges of the frame, and may be used to accomplish any of a variety of maneuvers for the satellite. The satellite may be a small satellite, such as a CubeSat satellite, for instance having a volume of about 1 liter, and a mass of no more than about 1.33 kg.