For a small satellite, every centimetre and every gram counts. That is why CubeSat propulsion design requires careful consideration of how a thruster will fit into the spacecraft and work alongside its other systems. Engineers need to assess not only the propulsion system’s performance but also its dimensions, mass, and integration requirements.
3D printing simplifies and speeds up the development of propulsion system components and the testing of new design options. It gives engineers greater freedom to design complex shapes and allows them to tailor components more precisely to the constraints of a small satellite. After manufacturing, the components undergo the necessary testing, so the team can confidently prepare them for integration into the system.
How 3D Printing Supports CubeSat Propulsion Design
In 3D printing, a part is created layer by layer. This differs from traditional manufacturing, in which a part is typically created from a solid block of material or assembled from several components.
For CubeSat propulsion this approach opens up new possibilities. Prototypes may be created faster. It is possible to test the designs in advance. On top of that, 3D printing allows for manufacturing complex shapes on demand.
1. Rapid Prototyping and Iteration
With 3D printing, you can produce a prototype of a part and verify whether its shape is suitable for further development. This helps evaluate the design even before the final component is manufactured.
Convenient way to test changes
Engineers can compare several variations of a part, change its shape or the placement of individual elements. This makes it easier to test different ideas and select the best option. However, 3D printing alone does not guarantee that development will take less time: timelines depend on the design and the necessary testing.
What Tests Are Needed
A prototype is not yet a component ready for use. Before use, it undergoes additional processing, dimensional and strength checks, as well as other tests. The specific set of tests depends on the component’s intended use.
2. Greater Design Freedom for CubeSat Propulsion Components
3D printing helps create parts with complex shapes and internal channels that are difficult to manufacture using conventional methods. The possibilities depend on the chosen technology and material, so the design is developed with these requirements in mind.
Why Shape Is Important for Powertrain Systems
A part’s shape affects its performance and how it fits among other components. Engineers take this into account during the design process, and the impact of the design on thruster performance is verified through calculations and testing.
3. A New Approach to Small Batches of Parts
3D printing can be convenient for prototypes and small batches of parts. Often, there is no need to build special tooling in advance. Additionally, the design can be tailored to a specific project.
How to Choose the Right Manufacturing Method
Cost and lead time are influenced by batch size, material, post-processing, and quality control. Therefore, 3D printing isn’t always cheaper or faster than traditional manufacturing. It’s especially important to compare both approaches if parts are needed in large quantities.
Before ordering parts for a satellite, clarify the following:
- What material is the part made of?
- What 3D printing technology was used?
- What tolerances and surface quality can be achieved?
- How are the quality and repeatability of the parts verified?
- Is post-printing processing or testing required?
3D printing helps to validate designs more quickly, experiment with complex shapes, and produce prototypes or small batches of parts. However, it is not always cheaper and does not guarantee that a part will be lighter or more reliable.
The benefits of 3D printing for a CubeSat propulsion system must be evaluated on a case-by-case basis for each part and mission, taking into account the material, manufacturing method, and test results.
If you are selecting a propulsion system for your CubeSat, review the specifications of the solutions and discuss the project requirements with the supplier in advance.
About SteamJet Space Systems
SteamJet Space Systems is a leading UK-based provider of high-performance satellite propulsion solutions. We specialise in water-based propulsion solutions designed specifically for CubeSats and Small Satellites (SmallSats), prioritising operational safety and rapid launch integration. All the SteamJet Space Systems thrusters are 3D-printed from Titanium.
By pioneering the use of green propellants and intelligent thermal engineering, SteamJet enables complex LEO (Low Earth Orbit) manoeuvres — including orbital maintenance, collision avoidance, and de-orbiting — without the risks associated with toxic hydrazine or high-pressure cold-gas systems, thereby advancing green propulsion for space missions.
Steamjet Propulsion Technology
Our modular systems are engineered for seamless integration and maximum safety compliance:
Steamjet TunaCan Thruster: A compact, high-efficiency solution for 1U-3U CubeSats.
Steamjet TunaTank Thruster: A safe, high-performance electrothermal propulsion system.
Steamjet Thruster One: Scalable propulsion for larger SmallSat constellations.
Discover how SteamJet’s sustainable space propulsion innovations are providing the safety and reliability required for the next generation of crewed and robotic missions. Contact our engineering team for technical specifications and ICDs.