High‐Impulse, Modular, 3D‐Printed CubeSat Electrospray Thrusters Throttleable via Pressure and Voltage Control

Abstract This study reports the proof‐of‐concept demonstration of novel, additively manufactured, droplet‐emitting electrospray emitter arrays for CubeSat thruster applications. The modular thruster design incorporates multiscale features by employing two different vat photopolymerization technologies, i.e., digital light processing for defining mesoscale features, and two‐photon polymerization for creating microscale features. The thruster design includes optimized, 50 µm‐diameter microfluidic channels to attain uniform emitter array operation. Devices with up to 8 modules of 4 emitters were tested in a vacuum to assess their performance. Stable and uniform electrospray emission was achieved across all emitters, with a near 100% transmission across the extractor. Both pressure (flow rate) and voltage modulation are investigated as methods for controlling the emitted current and, by extension, the thrust generated by the devices. The per‐emitter current followed a well‐known square root relationship with flow rate; in addition, a linear relationship between per‐emitter current and extractor voltage is observed. Compared to pressure control, modulating thrust via voltage control simplifies system design, eliminating the need for complex valves and enabling a wider throttle range. Estimated thrust and specific impulse are comparable to, or better than reported droplet‐emitting electrospray thrusters. These findings demonstrate the potential of additive manufacturing to implement electrospray propulsion hardware.