Electrically operated propellant is used to supplement the thrust provided by solid rocket motor (SRM) propellant to manage thrust produced by a SRM. The gas produced by burning the electrically operated propellant may be injected upstream of the nozzle to add mass and increase chamber pressure Pc, injected at the throat of the nozzle to reduce the effect throat area At to increase chamber pressure Pc or injected downstream of the throat to provide thrust vector control or a combination thereof. Certain types of electrically operated propellants can be turned on and off provided the chamber pressure Pc does not exceed a self-sustaining threshold pressure eliminating the requirement for physical control valves.

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.

Systems and methods for casting solid propellants include a mandrel for forming geometric features in a perforation of a propellant grain. In various embodiments, the mandrel includes a frangible portion that is removed from the propellant grain after the propellant grain has cured around the mandrel. A second portion of the mandrel may be left behind in the propellant grain. The mandrel may include a support structured disposed in the through hole of the mandrel. The support structure may include a plurality of longitudinal channels for directed exhaust gasses through the mandrel upon ignition of the propellant grain.

Systems and methods for casting solid propellants include a mandrel for forming geometric features in a perforation of a propellant grain. In various embodiments, the mandrel includes a frangible portion that is removed from the propellant grain after the propellant grain has cured around the mandrel. A second portion of the mandrel may be left behind in the propellant grain. The mandrel may include a support structured disposed in the through hole of the mandrel. The support structure may include a plurality of longitudinal channels for directed exhaust gasses through the mandrel upon ignition of the propellant grain.

A method of making a fuel grain for use in a rocket motor, the method comprising blending a first energetic nanoscale metallic compound and a second compound suitable to form a feedstock material for use in an additive manufacturing apparatus, the additive manufacturing apparatus operatively connected to a computing system, that provides additive manufacturing printing instructions to the additive manufacturing apparatus, permitting construction of an autonomously designed and optimized rocket fuel grain section; wherein the stochastic deposition simulation-assisted fuel grain geometries further comprise a plurality of agglutinated layers of solidified fuel grain compound, each layer of the plurality of layers comprising a plurality of blended and radially displaced beads of different radii, said radial displacement optionally optimized via competitive simulation programs, and wherein the system continuously mixes constituent materials in an inline/static mixer, with viscosity controlled via particle size variations, and material is deposited in a controlled atmosphere or vacuum.

A method of making a fuel grain for use in a rocket motor, the method comprising blending a first energetic nanoscale metallic compound and a second compound suitable to form a feedstock material for use in an additive manufacturing apparatus, the additive manufacturing apparatus operatively connected to a computing system, that provides additive manufacturing printing instructions to the additive manufacturing apparatus, permitting construction of an autonomously designed and optimized rocket fuel grain section; wherein the stochastic deposition simulation-assisted fuel grain geometries further comprise a plurality of agglutinated layers of solidified fuel grain compound, each layer of the plurality of layers comprising a plurality of blended and radially displaced beads of different radii, said radial displacement optionally optimized via competitive simulation programs, and wherein the system continuously mixes constituent materials in an inline/static mixer, with viscosity controlled via particle size variations, and material is deposited in a controlled atmosphere or vacuum.

A method of making a multi-grained fuel grain for a rocket is disclosed, the method comprising the steps of using at least one nozzle to extrude a first propellant in an additive manufacturing process, the first propellant comprising a multi-grained fuel grain, the multi-grained fuel grain forming the at least one void, the at least one void facilitating variation in internal ballistics, forming sensors, said sensors permitting continuous monitoring and continuous modification such that a user controls the ballistics profile of a rocket motor, forming an electrically-controlled second propellant in contact with and operatively coupled to the sensors; and wherein the additive manufacturing process uses at least at least one nozzle to extrude raw materials.

A method of making a multi-grained fuel grain for a rocket is disclosed, the method comprising the steps of using at least one nozzle to extrude a first propellant in an additive manufacturing process, the first propellant comprising a multi-grained fuel grain, the multi-grained fuel grain forming the at least one void, the at least one void facilitating variation in internal ballistics, forming sensors, said sensors permitting continuous monitoring and continuous modification such that a user controls the ballistics profile of a rocket motor, forming an electrically-controlled second propellant in contact with and operatively coupled to the sensors; and wherein the additive manufacturing process uses at least at least one nozzle to extrude raw materials.

An ignition system for a jet includes a squib. A solid propellant gas generator is ignitable by the squib and produces hot gas. An insulated hot gas accumulator is provided for storing the hot gas. A three-way hot gas valve is in fluid communication with the jet, the solid propellant gas generator, and the insulated hot gas accumulator. The three-way hot gas valve has a first condition establishing a first flow path from the solid propellant gas generator to the jet, a second condition establishing a second flow path from the solid propellant gas generator to the insulated hot gas accumulator, and a third condition establishing a third flow path from the insulated hot gas accumulator to the jet.

An ignition system for a jet includes a squib. A solid propellant gas generator is ignitable by the squib and produces hot gas. An insulated hot gas accumulator is provided for storing the hot gas. A three-way hot gas valve is in fluid communication with the jet, the solid propellant gas generator, and the insulated hot gas accumulator. The three-way hot gas valve has a first condition establishing a first flow path from the solid propellant gas generator to the jet, a second condition establishing a second flow path from the solid propellant gas generator to the insulated hot gas accumulator, and a third condition establishing a third flow path from the insulated hot gas accumulator to the jet.