NASA's Two-in-One Satellite Propulsion Demo Begins In-Space Test
NASA is testing two new micropropulsion technologies on the DUPLEX CubeSat deployed from the ISS, using polymer fibers to provide safe and affordable propulsion performance.
The DUPLEX CubeSat carries two complementary propulsion systems: a fiber-fed pulsed plasma thruster using Teflon for high-impulse pulsed thrust via arc discharge, ideal for orbital maneuvers; and a monofilament vaporization system inspired by 3D printers that heats Delrin polymer for continuous thrust, perfect for precision attitude control. The system will validate capabilities over two years by raising and lowering orbit, providing safe, affordable propulsion solutions for small satellites to support LEO economy and deep space missions.
Dual Propulsion Experiment (DUPLEX) deploys from the International Space Station December 2, 2025. Credit: NASA
NASA is working with commercial partners to create high-performing, reliable propulsion systems that will help small spacecraft safely maneuver in orbit, reach intended destinations across the solar system, and accomplish mission operations.
Two new micropropulsion technologies are being tested in space onboard a CubeSat called DUPLEX (Dual Propulsion Experiment) that deployed into low Earth orbit from the International Space Station on Dec. 2. The CubeSat is fitted with two thruster systems that use spools of polymer fibers to provide performance levels of propulsion comparable to existing systems but with greater safety during assembly and more affordability.
On orbit, DUPLEX will test its advanced propulsion systems by raising and lowering its orbit over two years, demonstrating the systems' capabilities to maintain a vehicle's orbit over time.
This propulsion technology employs an electric pulse to vaporize Teflon material and uses the resulting ions to deliver strong, efficient thrust while using very little fuel. It operates in pulsed mode, converting solid propellant into plasma jets through arc discharge to achieve high specific impulse propulsion.
Inspired by 3D printers, this propulsion technology heats and vaporizes a common polymer material known as Delrin to create continuous thrust. Similar to 3D printer filament feeding mechanisms, the system feeds solid polymer filament into a heating chamber where it vaporizes to form propulsive gas, providing stable continuous thrust.
The DUPLEX CubeSat integrates two complementary propulsion technologies: the pulsed plasma thruster for high-thrust maneuvers, and the monofilament vaporization thruster for precision attitude control and orbit maintenance.
Micropropulsion solutions enable a variety of cost-efficient capabilities necessary for operators in a bustling low Earth orbit economy, including: maintaining and adjusting orbits to avoid debris or nearby spacecraft; and coordinating maneuvers between spacecraft to perform maintenance, inspections, and other critical activities.
The systems tested on DUPLEX can also make spacecraft capable of lower cost extended missions in areas that are farther from Earth, such as the Moon and Mars. Technologies like those demonstrated onboard DUPLEX open the door for U.S. industry to provide efficient, affordable spacecraft systems for various space-based applications, building a stronger orbital economy to meet the needs of NASA and the nation.
The technologies demonstrated by DUPLEX represent a significant advance in small spacecraft propulsion. Traditional chemical propulsion systems pose safety hazards and high costs, while these two polymer fiber-based propulsion technologies dramatically improve safety and affordability while maintaining performance.
The pulsed plasma thruster provides high specific impulse and strong thrust suitable for orbital maneuvers, while the monofilament vaporization thruster offers continuous controllable micro-thrust ideal for precision attitude control. The combination of both systems gives small satellites complete maneuvering capability, laying the foundation for future constellation deployment, deep space exploration, and on-orbit servicing missions.
The DUPLEX spacecraft was developed by Champaign-Urbana Aerospace in Illinois. NASA's Small Spacecraft and Distributed Systems program at the agency's Ames Research Center in California's Silicon Valley supported the development, with funding from the Small Business Innovation Research program and a 2019 Tipping Point industry partnership award through the agency's Space Technology Mission Directorate.