NASA Testing USU's 3D-Printed Hybrid Rocket Motor for Safer Moon Landings

Experts at NASA’s Marshall Space Flight Center in Huntsville, Alabama, are conducting critical tests on a hybrid rocket system developed at Utah State University’s Propulsion Research Laboratory.

Stephen Whitmore, a professor in the Mechanical and Aerospace Engineering Department, worked alongside graduate students Ryan Thibaudeau and Jared Coen, as well as undergraduate students Josh Sorenson, Logan Mecham, Ava Wilkey and Cody White, to develop a 3D-printed hybrid rocket motor that offers smoother, safer descent performance and provides a more environmentally friendly alternative to traditional propulsion systems.

The rocket system was developed to support NASA’s Human Landing System, a transportation platform designed to carry astronauts to the lunar surface as part of the Artemis campaign. It also contributes to the Plume Surface Interaction project, which focuses on advancing modeling and testing to better understand how rocket exhaust plumes affect planetary landing sites.

The hybrid system being used in the PSI test-campaign leverages the High-Performance “Green” Hybrid Propulsion system, which has been in development for the past decade at USU.

Originally, this system was developed as an environmentally sustainable replacement for highly toxic propellants. This system is as safe and environmentally friendly as cold-gas systems but also offers a much higher performance level.

To achieve a soft touchdown, powerful engines are essential for a lander module to brake from lunar orbit.

"Although the PSI hybrid gas-generator system was not specifically designed as an in-space propulsion system, by the successful completion of this program under both ambient and vacuum-conditions and across three different test facilities, this 75-mm thrust chamber will be the most highly tested and well-characterized hybrid motor in history,” Whitmore said.