The breakthrough was delivered by Space Machines Company (SMC), in partnership with the CSIRO’s Lab22 facility, where the component was produced on a Nikon SLM Solutions SLM 280 2MA metal printer. Funding was provided through the iLAuNCH Trailblazer program.
The thruster will power SMC’s Optimus Viper spacecraft, an Australian-built platform designed for on-orbit inspection, servicing and logistics.
Unlike traditional thrusters, which require labour-intensive machining and brazing of copper and steel components, the new design uses multi-material laser powder bed fusion to combine two metals in a single build. High-strength steel provides structural integrity, while a copper alloy ensures high thermal conductivity for cooling. The result is a lighter, stronger thruster able to withstand repeated high-temperature firings.
iLAuNCH executive director Darin Lovett said the project was proof of Australia’s growing industrial capability, “We strive to build sovereign space capabilities by developing, manufacturing and operating space technology right here in Australia.”
SMC chief executive Rajat Kulshrestha said the company was rapidly scaling production of its Optimus Viper fleet: “By modifying our Scintilla thruster design to incorporate dual materials, we can experiment and optimise propulsion performance for mass-produced spacecraft.”
CSIRO senior scientist Dr Cherry Chen said the technology opened opportunities beyond space, adding, “By placing each material exactly where it’s needed, we can improve functionality, reduce waste and enable new designs across aerospace, automotive, biomedical and energy sectors.”
The iLAuNCH Trailblazer, led by the University of Southern Queensland with the Australian National University and the University of South Australia, is working with more than 25 partners to bridge the gap between research and commercialisation in the space industry.