Satellite and CubeSat thrusters > Warm Gas Propulsion Module for CubeSats and Microsatellites
Key highlights
Stellar Exploration's Warm Gas Green Propulsion Unit is a compact 2.5U system with a dry mass under 1,400 g that delivers >500 Ns total impulse across four thruster axes (with modifications available for a single axial configuration) at 25 mN nominal thrust and 55–60 s specific impulse. Featuring a thermally enhanced feed system engineered to operate in both warm-gas and cold-gas modes, it optimizes power consumption via an onboard Stellar Propulsion Controller that automates valve actuation, active heating, and health telemetry. Compliant with RPUG, AIAA-S-080, and SSCMAN 91-710 standards with AWS D17.1 Class A qualified pressure boundary welds, the unit is flight-qualified through 3-axis random vibration (14.1 g RMS), TVAC thermal cycling (-40°C to +60°C non-operational / 5°C to 50°C operational), helium leak testing, and hot-fire tests. Furthermore, its volume envelope, thruster positioning, and nozzle layout can be customized to fit specific mission and spacecraft architectures
Applications
- Orbital Delta-V Maneuvers: Performs reliable orbit raising, lowering, phase adjustments, plane changes, and collision avoidance maneuvers for microsatellites and CubeSats.
- RCS: Provides 6 DoF control, pointing adjustments, and reaction wheel desaturation utilizing its 4-thruster axis configuration.
- Primary Propulsion: Configurable with a single axial thruster to serve as the main propulsion engine for dedicated impulse-heavy missions.
- Constellation Phasing & Formation Flying: Delivers fine, repeatable impulse control for precise relative positioning and drag compensation.
- End-of-Life: Executes controlled de-orbit burns and complete system propellant venting/passivation to satisfy space debris mitigation compliance standards.
Key features
Propellant TypeR134a
Propellant Mass: 880 g (Customizable)
Dry Mass: 1390 g
Envelope: 2.5 U
Nominal Thrust: 25 mN
Specific Impulse: 55–60 s
Total Impulse > 500 Ns
Power Required< 20 W (including heaters)
Operating Temperature: 5°C to 50°C
Non-Operating Temperature: -40°C to +60°C
Proof Pressure: 1.5 × MEOP (25.5 bar)
Main Tank Burst Pressure: > 250 bar
Customization
Fully adaptable solution tailored to customer requirements and platform capabilities
Testing & qualification
- Safety & Standards Compliance: AFSPCMAN 91-710 / RPUG / AIAA-S-080 Compliant
- Welding Standards: Pressure boundary welds qualified in line with AWS D17.1 Class A (Visual, Surface Penetrant, X-ray, Metallography)
- Vibration Testing: 3-axis Random Vibration at 14.1 g RMS
- Leak Rate: Integrated Helium Leak Test threshold <1x10-9 mbar.l/s
- Pressure Cycling: Qualified for 150 cycles at MEOP
- Hot Fire Testing: Demonstrated plenum refills, nominal blowdown operation, and ON/OFF pulsing (10 ms, 30 ms, 50 ms) in vaccum enviroment
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Last updated: 2026-08-05
Warm Gas Propulsion Module for CubeSats and Microsatellites
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