‘Smart’ fuel tank makes small satellites cheaper and more sustainable
A ‘smart’ fuel tank for small satellites that makes space missions more affordable, reliable, and sustainable. The Dutch company Dawn Aerospace is working on this innovation, supported by the Netherlands Space Agency.
At first glance, there doesn’t seem to be much room for improvement regarding satellite fuel tanks. Yet, that is exactly what Dawn Aerospace has in mind. With a grant from the Netherlands Space Agency under the ESA’s ARTES-programme, the Dutch company is working on a new generation of ‘smart’ fuel tanks: the smart composite overwrapped pressure vessel (COPV).
‘We are a newspace company,’ says Jim Gilbert of Dawn Aerospace. ‘This means that we pursue rapid innovations, particularly for small and medium-sized satellites. The new fuel tank is part of our propulsion system, with which we aim to make satellites not only more affordable but also more sustainable.’
Tank provides feedback
Dawn Aerospace’s propulsion systems use a combination of nitrogen oxides and propene, which together cause less pollution than conventional rocket fuels, such as hydrazine. The substances are stored in tanks that are currently made of stainless steel, but will be made of aluminum in the future, with a carbon fiber composite wrapped around them. This is strong and light; exactly the properties you look for in a satellite mission.
Heating elements are integrated between the aluminum tank and the composite casing to maintain the fuel temperature. This makes the propulsion system less prone to errors and more efficient. Additionally, Dawn incorporates sensors into the outer composite layer. These sensors, supplied by the Belgian company Comm&Sens and made of fiberglass, measure the quality of the tank during construction, testing, and, in the future, in space.
‘In aerospace, it is common to temporarily attach sensors to the outside of products. We integrate sensors into the design of the tank instead. They remain in place and can thus provide valuable live feedback on what is happening inside the composite layers,’ says Gilbert. ‘With the data this generates, we can continuously improve our simulation models and thereby optimize development and the production process.’
That the sensors perform their job well was demonstrated during various tests of the new fuel tank. For instance, a leak was detected after a mechanical vibration test, and the integrated heating proved not yet robust enough. All these findings help to further perfect the design. If successful, the first heated, smart fuel tank will be delivered at the end of this year and launched in 2027.
Chicken or the egg
The development of the new tank will take a total of about four to five years. Thanks to support from the Netherlands Space Agency, Dawn Aerospace received funding from ESA’s ARTES innovation program. This solved a major chicken-or-the-egg problem, Gilbert explains: ‘A customer is willing to pay for a product that has proven itself. But first, you have to develop that product, and that requires money. Thanks to the NLSA’s support, we have been enabled to take a risk, grow our team and expertise, and bring a brand-new product to market relatively quickly.’
