Stellar Electric Gear Pump

The STREAM project proposes the development of an advanced electric gear pump for in-space propulsion systems, aimed at replacing traditional pressure-fed systems used in orbital transfer vehicles (OTVs), kick stages, and motorized dispensers. The consortium comprises five key organizations: Stellar Exploration s.r.o. (lead), SAB Aerospace s.r.o., LKE Engineering s.r.o., VZLU a.s, and Creotech Instruments S.A. The project is being developed under the FLPP (Future Launchers Preparatory Programme), FIRST! Propulsion initiative.

The primary use case focuses on integration with in-space transport vehicles such as IOSHEX (SAB) and RAVEN (Creotech). The proposed gear pump enables propulsion systems to operate with low-pressure tanks, reducing structural mass and increasing payload capacity. It also ensures consistent thrust performance, which is critical for precision maneuvers such as docking and satellite deployment.

The aim is to achieve a maximum output pressure of 500 psi and a flow rate of 10 mL/s. Technologically, the pump integrates a custom-designed brushless DC (BLDC) motor directly into the pump housing, minimizing moving parts and eliminating dynamic seals and the need for magnetic coupling. This approach reduces mechanical losses by approximately 20% and mass by up to 50%. The design includes precision-engineered gear sets, silicon carbide bushings for high wear resistance, and modular components for easy scalability. A breadboard model will be developed and tested under both functional and environmental conditions to reach Technology Readiness Level (TRL) 4–5.

Crucially, the development is explicitly focused on compatibility with green propellants, such as LMP-103s and hydrogen peroxide (HTP), supporting ESA’s sustainability goals and reducing toxicity and handling complexity in future missions.