Additively Manufactured Catalysts for AF-M315E Thrusters

Physical Sciences Inc. (PSI) and The ExOne Company propose to design and develop an Additively Manufactured (AM) catalyst structure to replace SOA catalyst beds in AF-M315E thrusters. This porous catalyst structure is based on ExOne’s binder jet 3-D printing technology, which is uniquely suited for high surface area catalyst structures. Ultrafine metal particles are not melted during this AM process, and will retain their size and morphology. This technique creates a highly porous catalytic structure without ceramic substrates or coating processes, resulting in a significant increase in catalyst lifetime and repeatability. In Phase I, the PSI/ExOne team will create full catalysts for 1 N thrusters that utilize porous structures to form discrete flow control geometries. Engineering designs and processes that result in maximum specific surface area will be used in Phase II for lifetime evaluation through 1 N thruster hot fire tests.