Properties and Behavior of 3D-Printed ABS Fuel in a 10 N Hybrid Rocket: Experimental and Numerical Insights

In a global landscape where the launch of satellites into space is growing exponentially, there is an increasing demand for propulsion solutions to perform various types of maneuvers. In this context, the present study aims to investigate a 3D-printed ABS (Acrylonitrile Butadiene Styrene)-based fuel for use in a 10 N-scale hybrid rocket in order to promote cost-effective and environmentally friendly access to space. As this material is currently unknown in this field and lacks a thermodynamic database, characterization of its pyrolysis process was carried out through a mixed approach combining experimental data and numerical simulations. The experiments show excellent performance of the H2O2-3D-printed ABS pair; despite the lack of information on its thermodynamically relevant quantities, it was possible to accurately reconstruct the fuel consumption profile as well as its regression rate and the spatial and temporal average values using the numerical model and Arrhenius parameters derived in this work. The methodology and results obtained herein represent tools that can be useful for the design of small-scale rockets using 3D-printed ABS-based fuels as well as a starting point for the development and analysis of the complex geometries made possible through additive manufacturing.