This research investigated the 3D printing and burning of fuel grains with complex geometry and the development of software capable of modeling and predicting the regression of a cross-section of these complex fuel grains. The software developed did predict the geometry to a fair degree of accuracy, especially when enhanced corner rounding was turned on. The model does have some drawbacks, notably being relatively slow, and does not perfectly predict the regression. If corner rounding is turned off, however, the model does become much faster; although less accurate, this method does still predict a relatively accurate resulting burn geometry, and is fast enough to be used for performance-tuning or genetic algorithms. In addition to the modeling method, preliminary investigations into the burning behavior of fuel grains with a helical flow path were performed. The helix fuel grains have a regression rate of nearly 3 times that of any other fuel grain geometry, primarily due to the enhancement of the friction coefficient between the flow and flow path.

A thrust augmented nozzle for hybrid rocket systems is investigated. The design lever-ages 3-D additive manufacturing to embed a helical fuel port into the thrust chamber of a hybrid rocket burning gaseous oxygen and ABS plastic as propellants. The helical port significantly increases how quickly the fuel burns, resulting in a fuel-rich exhaust exiting the nozzle. When a secondary gaseous oxygen flow is injected into the nozzle downstream of the throat, all of the remaining unburned fuel in the plume spontaneously ignites. This secondary reaction produces additional high pressure gases that are captured by the nozzle and significantly increases the motor’s performance. Secondary injection and combustion allows a high expansion ratio (area of the nozzle exit divided by area of the throat) to be effective at low altitudes where there would normally be significantly flow separation and possibly an embedded shock wave due. The result is a 15 percent increase in produced thrust level with no loss in engine efficiency due to secondary injection. Core flow efficiency was increased significantly. Control tests performed using cylindrical fuel ports with secondary injection, and helical fuel ports without secondary injection did not exhibit this performance increase. Clearly, both the fuel-rich plume and secondary injection are essential features allowing the hybrid thrust augmentation to occur. Techniques for better design optimization are discussed.