Conceptual design of a 1 kN hybrid rocket engine manufactured with additive technology

This research, conducted at the Chemical Propulsion Laboratory (CPL) of the University of Brasília (UnB), focuses on the conceptual design, manufacturing, and testing a 1 kN hybrid rocket engine utilizing additive manufacturing technology. The initiative is a collaborative effort, fostering a national alliance among industry, research institutes, and academia to propel Brazil's capabilities in aerospace propulsion and international collaboration, covering various facets of the project. Skills range from conceptual design and detailed drawing to numerical simulation, additive manufacturing, structural analysis, and control system design. The study justifies the application of 3D printing in hybrid rocket engines by outlining specific objectives, including defining engine characteristics, adapting test benches and feed systems, establishing structural requirements, and rationalizing critical design decisions. The research targets a TRL of 6 for the combustion chamber, pioneering integrating structural and thermal tools into additive manufacturing processes. The secondary objective is to develop a 3D-printed engine’s liquid cooling system as an intermediate step toward developing liquid rocket propulsion systems in future projects. Project phases have progressed through defining technical requirements, preliminary engine design, and analytical calculations of flow and heat transfer in the engine. The ongoing detailed design phase incorporates numerical optimization, material selection, and fine-tuning of the data acquisition system. Subsequent stages will involve test bench preparation, component assembly, and system integrity testing. By adhering to European Cooperation for Space Standardization (ECSS) standards, the project ensures compliance with propulsive system development requirements, incorporating critical reviews before advancing to subsequent phases. Envisioned as a technological demonstrator, the hybrid rocket engine with cooling capabilities advances hybrid rocket technology and stimulates growth in space systems by supporting startups and spin-offs. Project outcomes include defining the engine's envelope and enabling detailed numerical design through flow simulation and structural analysis. The innovative additive manufacturing approach significantly reduces development costs, paving the way for a diversified portfolio of modern aerospace products within the Brazilian industry. This research contributes not only to the advancement of hybrid rocket technology but also to the broader landscape of aerospace innovation and sustainable development in Brazil.