NASA Tests Next-gen Micropropulsion in Orbit with DUPLEX CubeSat

Our Bureau - : Dec 19, 2025 - : 3:37 am

NASA has begun in-orbit trials of two new micropropulsion systems that could transform the way small spacecraft manoeuvre, survive and operate in low Earth orbit and far beyond. The technologies are being tested aboard a CubeSat called DUPLEX (Dual Propulsion...

To read the full article, please log in or enter your email below:

As commercial and government operators increasingly turn to small spacecraft for science, communications and inspection missions, propulsion remains one of the most limiting factors. Small satellites often struggle to change or maintain orbits, avoid debris or coordinate rendezvous with other spacecraft. NASA’s latest experiment aims to address that gap by developing miniature propulsion systems that are not only efficient and capable, but also safer to assemble and more affordable to manufacture.

A CubeSat Carrying Two Different Engines

DUPLEX carries two independent thruster systems, both of which rely on spools of polymer fibre rather than traditional propellants. Each system uses the same guiding principle: feed a solid polymer into a mechanism that vaporises the material and expels it as thrust. But the two approaches achieve this in very different ways.

The first technology is a fibre-fed pulsed plasma thruster. It uses an electric pulse to vaporise a small amount of Teflon, creating a burst of plasma. The resulting ions are expelled at high speed, generating short, powerful bursts of thrust. Because each pulse uses only a tiny amount of material, the system is designed to deliver high performance while consuming minimal fuel.

The second system, known as a monofilament vaporisation propulsion system, takes its inspiration from 3D printers. A thin strand of Delrin polymer is heated until it vaporises. The expanding gas is then channelled through a small nozzle to produce low but continuous thrust. For small spacecraft that need slow, controlled adjustments over time, this method offers a simple and reliable solution.

Both systems promise propulsion performance comparable to existing microthrusters but with significant advantages: lower cost, fewer safety risks during assembly, easier integration and longer operational life.

A Long Test Campaign in Low Earth Orbit

Over the next two years, NASA will monitor how DUPLEX performs as it raises and lowers its orbit. The aim is to demonstrate whether the dual-engine configuration can maintain a spacecraft’s orbit, counter atmospheric drag and perform controlled manoeuvres. If successful, the technology could provide a new class of propulsion solutions for an increasingly crowded orbital environment.

Micropropulsion is becoming essential as low Earth orbit fills with satellites. Operators need ways for small spacecraft to avoid debris, navigate around congested areas, and position themselves accurately for inspections, maintenance or formation flying. The propulsion systems aboard DUPLEX are designed to give CubeSats and other small satellites these capabilities without the cost or complexity of traditional chemical thrusters.
NASA also sees wider opportunities. The same propulsion systems could support low-cost missions to the Moon and Mars, allowing small spacecraft to operate farther from Earth without requiring large propellant tanks.

A Commercial Partnership with National Implications

The DUPLEX spacecraft was developed by Champaign-Urbana Aerospace, an Illinois-based company specialising in microspacecraft technologies. The project was funded through NASA’s Small Business Innovation Research (SBIR) programme and a 2019 Tipping Point award from the agency’s Space Technology Mission Directorate. NASA’s Small Spacecraft and Distributed Systems programme at Ames Research Center is overseeing the experiment.

By supporting commercially developed propulsion systems, NASA aims to help create a stronger industrial base in the United States for small-satellite manufacturing. Affordable, high-performance propulsion is seen as a critical building block of the country’s broader orbital economy — enabling new types of services, from rapid-response Earth observation to in-orbit inspection and repair.

As DUPLEX begins its long demonstration flight, NASA hopes the experiment will show how small spacecraft can gain big-mission capabilities. If these microthrusters perform as intended, the next generation of CubeSats may no longer drift passively through orbit, but manoeuvre with purpose — avoiding hazards, working together and venturing farther than ever before.

Nasa / Duplex-dual-propulsion-experiment /

MORE NEWS