Yuki Funami

The objective of the project was to develop a hybrid rocket with a recovery system that would facilitate reuse. The rocket was successfully developed, launched and recovered. A two-stage parachute deployment system was developed and utilized, incorporating a non-pyro separation and a low-shock device. Notably, the non-pyro separation device plays a pivotal role in enabling the successful separation of a hybrid rocket, thereby ensuring its operation is free from explosive hazards. The launch took place on 14 December 2024, and all equipment was successfully recovered, except for the nose cones, the antenna-deployable GPS beacon and the motor case. The Ti-6Al-4V oxidizer tank, an important part that can be reused, was recovered with damage only to the outlet fitting. The tank was successfully repaired and passed a pressure test. This marks the first step in creating a reusable hybrid rocket.

To achieve low-cost and on-demand launches of microsatellites, the authors have been researching and developing a micro hybrid rocket since 2014. In 2018, a ballistic launch experiment was performed using the developed hybrid rocket, where it reached an altitude of about 6.2 km. The rocket engine had a 3D-printed solid fuel grain made of acrylonitrile butadiene styrene (ABS) resin in combination with a nitrous oxide oxidizer. The fuel grain port had a star-fractal swirl geometry in order to increase the surface area of the port, to promote the laminar–turbulent transition by increasing the friction resistance, and to give a swirling velocity component to the oxidizer flow. This overcame the hybrid rocket’s drawback of a low fuel regression rate; i.e., it achieved a higher fuel gas generation rate compared with a classical port geometry. In 2021, the hybrid rocket engine was scaled up, and its total impulse was increased to over 50 kNs; it reached an altitude of 15 km. In addition to the engine, other components were also improved, such as through the incorporation of lightweight structures, low-shock separation devices, a high-reliability telemetry device, and a data logger, while keeping costs low. The rocket was launched and reached an altitude of about 10.1 km, which broke the previous Japanese altitude record of 8.3 km for hybrid rockets. This presentation will report on the developed components from the viewpoint of system design and the results of the ballistic launch experiments.

To achieve low-cost and on-demand launches of micro satellites, the authors have been researching and developing a micro hybrid rocket since 2014. In 2018, a ballistic launch experiment was performed using the developed hybrid rocket, where it reached an altitude of about 6.2 km. The rocket engine had a 3D-printed solid fuel grain made of acrylonitrile butadiene styrene (ABS) resin in combination with a nitrous-oxide oxidizer. The fuel grain port had a star-fractal swirl geometry in order to increase the surface area of the port, to promote the laminar-turbulent transition by increasing the friction resistance, and to give a swirling velocity component to the oxidizer flow. This overcame the hybrid rocket’s drawback of low fuel regression rate; i.e., it achieved a higher fuel-gas generation rate compared with a classical port geometry. In 2021, the hybrid rocket engine was scaled up and its total impulse was increased to over 50 kNs for reaching an altitude of 15 km. In addition to the engine, other components were also improved, such as through incorporation of lightweight structures, low-shock separation devices, a high-reliability telemetry device and data logger, while keeping costs low. The rocket was launched and reached an altitude of about 10.1 km, which broke the previous Japanese altitude record of 8.3 km for hybrid rockets. The presentation will report on the developed components from the viewpoint of system design and the results of the ballistic launch experiments.

A three-dimensional-printed solid fuel grain with a star-fractal swirl port was developed to improve the fuel regression rate of hybrid rockets. The printing material used for the grains was an acrylonitrile-butadiene-styrene resin. Nitrous oxide was employed as the oxidizer. Combustion experiments on the hybrid rocket engine with the developed grain showed that the star-fractal swirl port appeared to improve the thrust and specific impulse compared to the classical circular and star-fractal ports when tested using the same oxidizer mass flow rate that is a controllable parameter of hybrid rocket engines. After the experiments, the burned grains were cut and the grain web thicknesses were measured to evaluate the local regression rate. It was found that the fuel surface regressed more rapidly near the concave parts of the star fractal rather than the convex parts. Next, the measured local regression rates were axially averaged. The axially-averaged local regression rates of the star-fractal swirl port were much higher than those of the star-fractal and circular ports. Finally, a numerical approach using the level set method for evaluating time- and space-averaged regression rate was developed. This approach was validated by comparing the space-averaged regression rates with the axially-averaged local rates.