Space Technology: Game Changing Development Deep Space Engine (DSE) 100 lbf and 5 lbf Thruster Development and Qualification

Science mission studies require spacecraft propulsion systems that are high-performance, lightweight, and compact. Highly matured technology and low-cost, short development time of the propulsion system are also very desirable. The Deep Space Engine (DSE) 100-lbf thruster is being developed to meet these needs. The overall goal of this game changing technology project is to qualify the DSE thrusters along with 5-lbf attitude control thrusters for space flight and for inclusion in science and exploration missions. The aim is to perform qualification tests representative of mission duty cycles. Most exploration missions are constrained by mass, power and cost. As major propulsion components, thrusters are identified as high-risk, long-lead development items. NASA spacecraft primarily rely on 1960s' heritage in-space thruster designs and opportunities exist for reducing size, weight, power, and cost through the utilization of modern materials and advanced manufacturing techniques. Advancements in MON-25/MMH hypergolic bipropellant thrusters represent a promising avenue for addressing these deficiencies with tremendous mission enhancing benefits. DSE is much lighter and costs less than currently available thrusters in comparable thrust classes. Because MON-25 propellants operate at lower temperatures, less power is needed for propellant conditioning for in-space propulsion applications, especially long duration and/or deep-space missions. Reduced power results in reduced mass for batteries and solar panels. DSE is capable of operating at a wide propellant temperature range (between -22 F and 122 F) while a similar existing thruster operates between 45 F and 70 F. Such a capability offers robust propulsion operation as well as flexibility in design. NASA's Marshall Space Flight Center evaluated available operational Missile Defense Agency heritage thrusters suitable for the science and lunar lander propulsion systems.