Lab-on-PCB for space propulsion: Integrated membraneless micro-ignitor for MEMS solid propellant thruster

Existing micro-ignitors face significant challenges in terms of durability, mass production, and upscaling, mainly due to the use of membranes as critical components. Thin membranes offer a short ignition delay but lack durability, while thick membranes provide durability at the expense of a long ignition delay. Consequently, achieving both control performance and durability simultaneously remains a challenge. In this study, we propose a novel approach to address these limitations through the development and fabrication of a membraneless micro-ignitor integrated onto a printed circuit board (PCB) for a MEMS solid propellant thruster. This integration demonstrates the potential of seamlessly integrating propulsion and satellite electronic control systems. Our approach leverages the lab-on-PCB technique and stencil printing process as key concepts. The PCB-integrated micro-ignitor is designed following the lab-on-PCB concept, facilitating the mounting and electrical control of the solid propellant and coated heater. The components of the ignitor, solid propellant, and heater are mounted onto the PCB through stencil printing, a surface mount technology process commonly used in PCB manufacturing. During this process, we introduced a heater design guideline derived from a parametric study to minimize performance deviation. Furthermore, the proposed ignitor undergoes rigorous durability tests and combustion experiments to evaluate its mechanical and ignition characteristics. Results indicate that the membraneless PCB micro-ignitor exhibits superior structural stability compared to conventional membrane-based micro-ignitors. [Display omitted] •Novel, scalable membraneless micro-ignitor concept introduced.•Successful lab-on-PCB integration of critical components.•Durable heater achieved via CNT paste stencil printing.•Reproducibility of the micro-ignitor rigorously assessed.•Exhaustive evaluation of ignition characteristics of the micro-ignitor.