MIT Engineers Revolutionize Space Travel with Fully 3D-Printed Electrospray Engine
The future of space exploration just got a lot more accessible thanks to an innovative breakthrough from MIT engineers. Their latest development, a fully 3D-printed electrospray engine, could transform the way small satellites maneuver in orbit, making space technology more affordable and adaptable than ever before.
A Game-Changer for Small Satellites
Electrospray engines work by applying an electric field to a conductive liquid, producing a jet of tiny charged droplets that generate thrust. These engines are ideal for small satellites, known as CubeSats, which are widely used for academic research and commercial applications.
Traditional electrospray thrusters are complex and expensive to produce, requiring semiconductor cleanroom fabrication. This limits accessibility to only well-funded organizations and significantly slows down production. But MIT’s new 3D-printed thruster could change that, offering a low-cost, rapid-manufacturing alternative that could even be produced in space.
Innovation Through 3D Printing
MIT’s researchers developed a novel modular approach by combining two different types of vat photopolymerization printing (VPP), a high-precision 3D printing method. Their design includes a 3x3 array of cone-shaped emitters, forming a system of interconnected modules that work together to create a stable and uniform thrust.
By utilizing two-photon printing for the ultra-fine emitter tips and digital light processing for the larger components, the team achieved an optimal balance of precision and scalability. The result? A fully functional thruster that outperforms existing droplet-electrospray engines in both efficiency and adaptability.
Democratizing Space Hardware
One of the most exciting aspects of this development is its potential for in-space manufacturing. With this technology, astronauts could print replacement engines on demand, eliminating the need for costly and time-consuming resupply missions from Earth. This aligns with the broader goal of making space exploration more self-sufficient and cost-effective.
MIT’s approach also introduces a more flexible method for satellite propulsion. The researchers discovered that adjusting the voltage applied to the engine allowed for a wider range of thrust control. This means future electrospray thrusters could operate without complex networks of pipes and valves, making them lighter, simpler, and even more efficient.
What’s Next?
This breakthrough is just the beginning. The MIT team plans to further refine their technology by developing denser and larger emitter arrays and exploring multi-electrode designs for improved thrust control. They also aim to test a CubeSat equipped with a fully 3D-printed electrospray engine in an actual space environment.
As the space industry continues to grow, advancements like MIT’s 3D-printed thruster pave the way for more accessible and affordable satellite technology. This innovation is a major step toward democratizing space research and ensuring that future missions can adapt quickly and efficiently in orbit.
With 3D printing now a viable solution for high-performance space hardware, the possibilities for small satellites—and beyond—are limitless. The stars may be closer than we think!