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Currently, there is great interest in the development of high-power electric propulsion (EP) devices that can be employed in missions requiring >100 kW levels of propulsive power. Of the candidates for such thrusters, the Nested-channel Hall thruster (NHT) has been shown to be particularly scalable to this mission requirement. To this end, the University of Michigan’s Plasmadynamics and Electric Propulsion Laboratory (PEPL), in conjunction with both the Air Force Research Laboratory (AFRL) and NASA, has developed a 100-kW-class NHT called the X3. While bringing the X3 to test-ready status, a number of developmental and facility-related challenges were encountered and overcome. This paper presents these challenges and the lessons learned associated with the X3’s design, fabrication, and testing as a case study to inform other high-power EP development efforts.

Electric Propulsion of a Different Class: The Challenges of Testing for MegaWatt Missions