Experimental investigation of 3D-printed tubular and swirl star grains as solid fuels for hybrid rocket engines

Document Type : Original Article

Authors

1 PhD student, Aerospace Engineering Department, Military Technical College, Egypt.

2 Associate Professor, Aerospace Engineering Department, Military Technical College, Egypt.

10.1088/1742-6596/2616/1//asat.2025.453560

Abstract

This study investigates using 3D-printed Acrylonitrile Butadiene Styrene (ABS) polymers as fuels for hybrid rocket engines through 27 static fire experiments. It evaluates the performance of ABS fuel grains across various motor sizes and compares the effects of direct and swirl injection in ABS/Gox hybrid engines. Regression rate relations with oxidizer mass flux are established for three configurations: a modified one-inch motor with ABS fuel tubular grain and swirl star grain with the modified motor. The swirl injection enhances the mixing and combustion efficiency, leading to increased regression rates. This research highlights the advantages of swirl injection in optimizing hybrid rocket performance and contributes to advancements in hybrid rocket technology. To enhance the fuel regression rate of hybrid rockets, a solid fuel grain featuring a star swirl reverse port was 3D printed using ABS fuel, with Gox as the oxidizer. Tests of the engine's combustion with this grain indicated that, at a constant oxidizer mass flow rate, the star-swirl reverse improved both thrust and specific impulse compared to tubular and traditional circular port grains.
International Conference on Aerospace Sciences and Aviation Technology
Volume 21, Issue 21
21st International Conference on Aerospace Sciences & Aviation Technology, ASAT 21, 2025.
September 2025
Pages 1-11

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