Case Study: Applied Ion Systems achieves cost‑efficient electric propulsion for nano‑ and pico‑satellites with Xometry

Entrepreneur Levels the Field in the Aerospace Industry With Miniature Propulsion System

Applied Ion Systems (AIS) is a small research startup led by Michael Bretti that develops open‑source electric propulsion systems for nano‑ and pico‑satellites. AIS needed a way to source increasingly complex, high‑precision parts quickly and affordably to iterate on thruster designs; to do that they turned to Xometry for CNC machining, 3D printing and rapid prototyping services, along with Xometry’s Instant Quoting Engine and wide material selection.

Xometry supplied CNC‑machined components (e.g., 7075‑T6 aluminum tanks, 1018 steel thruster heads, copper anodes) and high‑performance 3D‑printed parts (Somos PerFORM insulators), enabling AIS to build the AIS‑AHT1‑PQ Pico Anode‑Layer Hall Thruster. The resulting system weighs under 300 grams, measures 42 × 42 × 56 mm (~1/8U), has flown on a CubeSat, and demonstrates how Xometry’s faster, lower‑cost fabrication and rapid iteration significantly lower the barrier to entry versus traditional $50,000+ propulsion options.

Applied Ion Systems

Michael Bretti

Founder