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.

A high density, generally recognized as safe, hybrid rocket motor is described, having a density-specific impulse similar to a solid rocket motor, with good performance approaching or equal to a liquid rocket motor. These high density hybrid motors resolve the packaging efficiency/effectiveness problems limiting the application of safe, low cost hybrid motor technology.

A high density, generally recognized as safe, hybrid rocket motor is described, having a density-specific impulse similar to a solid rocket motor, with good performance approaching or equal to a liquid rocket motor. These high density hybrid motors resolve the packaging efficiency/effectiveness problems limiting the application of safe, low cost hybrid motor technology.

A rocket motor includes at least one inert rod. The inert rod has a groove that extends along the length of the inert rod. The groove may be machined by a lathe, die, and/or CNC machine, such that the groove is configured helically around the rod. A reactive wire is inserted into the groove along the length of the inert rod. The grooved inert rod, and the reactive wire together constitute the burn rate enhancer assembly. The rocket motor is configured such that the burn rate enhancer assembly is inserted into a rocket motor casing. The rocket motor casing is then filled with a burnable propellant grain, the highly loaded grain, which is in a liquid or semi-solid state. The highly loaded grain then cures in the rocket motor casing around the burn rate enhancer assembly.

A rocket motor includes at least one inert rod. The inert rod has a groove that extends along the length of the inert rod. The groove may be machined by a lathe, die, and/or CNC machine, such that the groove is configured helically around the rod. A reactive wire is inserted into the groove along the length of the inert rod. The grooved inert rod, and the reactive wire together constitute the burn rate enhancer assembly. The rocket motor is configured such that the burn rate enhancer assembly is inserted into a rocket motor casing. The rocket motor casing is then filled with a burnable propellant grain, the highly loaded grain, which is in a liquid or semi-solid state. The highly loaded grain then cures in the rocket motor casing around the burn rate enhancer assembly.

A solid-propellant rocket engine (1) has a casing (2) and a thermal protection (15) internally coating the casing and delimiting a housing (17), which contains a mass of solid propellant (3); the thermal protection has a fixed portion (22) and at least one movable portion (23) that adheres to the mass of solid propellant (3) and can be moved from a back position to a forward position with respect to the fixed portion (22) through a thrust system obtained by pressuring a chamber 31 provided by installing a membrane 32 between the fixed portion 22 and the movable portion 23; the engine is tested by verifying the adhesion of the mass of solid propellant (3) to the movable portion (23) after having moved the movable portion (23) to the forward position by means of a thrust directed from the fixed portion towards the mass of solid propellant (3).

A solid-propellant rocket engine (1) has a casing (2) and a thermal protection (15) internally coating the casing and delimiting a housing (17), which contains a mass of solid propellant (3); the thermal protection has a fixed portion (22) and at least one movable portion (23) that adheres to the mass of solid propellant (3) and can be moved from a back position to a forward position with respect to the fixed portion (22) through a thrust system obtained by pressuring a chamber 31 provided by installing a membrane 32 between the fixed portion 22 and the movable portion 23; the engine is tested by verifying the adhesion of the mass of solid propellant (3) to the movable portion (23) after having moved the movable portion (23) to the forward position by means of a thrust directed from the fixed portion towards the mass of solid propellant (3).

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 high density, generally recognized as safe hybrid rocket motor is described which has a density-specific impulse similar to a solid rocket motor, with good performance approaching or equal to a liquid rocket motor. These high density hybrid motors resolve the packaging efficiency/effectiveness problems limiting the application of safe, low cost hybrid motor technology.