This NASA SBIR Phase I proposal presents an unprecedented laser additive manufacturing system for making Hall-effect thruster discharge channels, by using a pulsed fiber laser. It is the enabling technology for manufacturing desired density and repeatability. With our successful history in AM and SM processing, this proposal has a great potential to succeed. A proof of concept demonstration along with simulation will be carried out and samples will be delivered at the end of Phase 1. Prototypes in compliance with the discharge channel requirements will be delivered at the end of Phase II.
In addition to NASA’s discharge channel manufacturing, the proposed pulsed laser AM process can also be used in other applications, such as space vehicle, aircraft, and satellite manufacturing. PolarOnyx will develop a series of products to meet various requirements for commercial/military deployments.