SBIR-STTR Award

On January 11, 2007 China conducted its first anti-satellite missile test, deliberately destroying another Chinese satellite. It demonstrated the vulnerability of US satellites to enemy combatants. Critical satellites could be destroyed, reducing US military coverage until the satellite is replaced. It can take more than 2 years to build, launch, and replace a non-operational satellite. High delta-V (or highly mobile) satellites would reduce the replacement time to as little as weeks: satellites in one orbit could be moved to another. Low delta-V capacity hinders DoD programs such as the LEO missile warning layer, ISR (intelligence, surveillance, reconnaissance) layer, and LEO communications. Electric propulsion can solve this problem by providing high delta-V capacity to small satellites. Commercial satellite manufacturers recognize these

Benefits:
over 500 commercial small satellites use electric propulsion. The first US commercial satellite to use electric propulsion launched in 2004; since then only 2 AFRL technology demonstration missions have used electric propulsion on small satellites. The US military has found it difficult to integrate and test electric propulsion. Apollo Fusion's ACE Max electric propulsion system is an engine for satellites. ACE Max allows every satellite to be a highly mobile satellite, by providing high delta-V capability at low cost with fast and easy integration into customer satellites. ACE Max is a complete propulsion system including a Hall thruster, PPU, robust software, a space-heritage tank, and a propellant feed system. Satellites with ACE Max are 10 times more mobile than typical Air Force satellites. Numerous USAF missions are delayed because of the time it takes to complete Acceptance Testing (continuity, isolation, vibe, performance, TVAC, thermal cycles, etc.) of the propulsion system. Apollo has developed a process for more quickly completing this testing on a satellite panel that has the prop system already integrated. The system is delivered to satellite manufacturers fully assembled and acceptance tested by Apollo Fusion, with no further testing required by the satellite integrator. This unique approach reduces the time and cost to integrate our electric propulsion system by approximately 75% compared to traditional approaches.

Apollo Fusion has developed an integrated electric propulsion module for the commercial satellite market: ACE (Apollo Constellation Engine). The integrated propulsion module supports faster delivery and cheaper/easier integration in the satellite. This SBIR Phase II program will support R&D and defense specified modifications of ACE to allow its use in USG missions. The modifications to increase electric propulsion delta-v capability will support extraordinary mobility satellites, which enable USG missions in hard to access orbits. The SBIR will design, qualify, and deliver a fully integrated propulsion module for a specific AFRL-CRI mission. Apollo Fusion will work with the satellite manufacturer to design a mission-specific integrated propulsion module. Apollo Fusion will design a test plan for qualification testing and acceptance testing that supports the increased robustness and reliability needs of AFRL’s mission. Apollo Fusion will conduct R&D testing and analysis to support the test plan. Apollo Fusion will build a defense-specific qualification module to complete qualification testing. Finally, Apollo Fusion will deliver an integrated flight propulsion module to AFRL. At the end of this program Apollo Fusion’s integrated propulsion module will be available for use in USG missions as off-the-shelf hardware.