Abstract. Domestically, microthrusters operating based on the catalytic decomposition of a high-energy chemical compound – hydrazine (N2H4) – are used for the attitude control systems of several spacecraft (SC). Both compact briquetted metal catalysts, such as K-53, and supported catalysts, such as K-201, are used in these engines. The K-53 metal catalyst is used in thermocatalytic thrusters. However, due to the low activity of this catalyst at temperatures below 100 °C, its preheating temperature before thruster startup must be above 350 °C. This requires high power consumption aboard the spacecraft. Highly active iridium-based catalysts offer advantages in terms of activity and bed loading capacity. The K-201 catalyst is used in Russia. Like all highly active catalysts, it utilizes iridium (29–33 %) as an active component, as it is the most active metal in the hydrazine decomposition reaction. The feasibility of creating a combined catalyst that integrates the best qualities of both types is investigated. Additive manufacturing, also known as 3D printing, aids in resolving the issue of the creation and manufacturing methods of a new metal catalyst. The advent of 3D printing has opened new possibilities for manufacturing reactor parts, organizing propellant combustion processes in power systems, and creating complex internal structures of chemical reactors. The most attractive aspect of additive manufacturing is that it enables the production of parts with any desired configuration. The layer-by-layer melting of powders involves a stage of porous structure formation, which can be investigated as a support for a porous catalyst. These possibilities are explored.

Keywords: catalyst, iridium catalyst, highly porous cellular materials, metal catalysts, 3D printing, selective laser melting, additive manufacturing, new technologies

For citation: Volkova T. V., Zherebtsov V. L., Levikhin A. A. Development of a technology for manufacturing structured catalysts and rocket engine catalyst beds using 3D printing. Aerospace Engineering and Technology. 2026. Vol. 4, no. 1, pp. 75–91. (In Russ.) https://doi.org/10.52467/2949-401X-2026-4-1-75-91; https://elibrary.ru/IQUEUO

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