Smart Micronozzles for Next-Generation Supercritical Fluid-Based Microthrusters

forthcoming

The STELLAR project aims to demonstrate the proof-of-concept for a novel micropropulsion technology —Smart Supercritical Fluid-Based Micronozzles (SSFMs)— designed to meet the growing needs of CubeSats and small satellites. These miniaturized propulsion units will use supercritical fluids to deliver compact, efficient, and tunable thrust, addressing critical limitations in current systems, such as low thrust density, poor scalability, and integration complexity. SSFMs combine advanced microfabrication, integrated sensor control, and real-time flow modulation to enable both fine attitude control and high-agility maneuvers using non-toxic, high-energy fluids. Compared to state-of-the-art cold-gas or electrothermal thrusters, SSFMs are expected to deliver up to 5x higher thrust density, reduce volume by up to 30%, and cut weight by up to 20%, while also enhancing responsiveness and system autonomy. Building on results from the ERC-funded SCRAMBLE project, STELLAR will fabricate and test functional SSFM prototypes under representative pressure and thermal conditions, validating key performance metrics including thrust, impulse, and flow stability. The project will target a final technology readiness level (TRL) of 4, representing laboratory validation of the integrated prototype. Supporting activities include advanced simulations for micronozzle optimization, stakeholder engagement, and intellectual property protection. In parallel, the SSFM architecture offers cross-sector potential in biomedical microfluidics, electronics cooling, and soft robotics; domains that share similar demands for compact, thermally efficient fluidic control. By addressing both space and cross-sector challenges, STELLAR will bridge the gap between advanced microfluidics research and next-generation space technologies, enabling more agile, sustainable, and mission-adaptive propulsion for small spacecraft.