LEGOs, Laughing Gas and Lunar Landings: Innovative Hybrid Rocket to Support Future NASA Missions
After a decade of dedicated research, mechanical and aerospace engineering professor Stephen "Tony" Whitmore has reached a major milestone in advancing next-generation propulsion technology.
Tony Whitemore, a USU Professor Emeritus with decades of experience and a growing list of successful alumni, has reached a career milestone after NASA announced it will further develop his patented hybrid rocket motor technology. Photo credit: Matt Jensen
Building on more than 25 years of experience with NASA, Whitmore has led the development of a 3D-printed hybrid rocket motor that has undergone critical testing at NASA's Marshall Space Flight Center in Huntsville, Alabama, with further evaluations scheduled at NASA's Langley Research Center.
Designed in Utah State University's Propulsion Research Laboratory, the rocket system supports NASA's Human Landing System — the platform that will carry astronauts to the lunar surface as part of the Artemis campaign. It also plays a central role in the Plume Surface Interaction project, which examines how rocket exhaust affects planetary landing sites, a crucial factor for future exploration.
At the heart of this breakthrough is the High-Performance "Green" Hybrid Propulsion system, originally created as a sustainable alternative to toxic propellants. The solid fuel cell is 3D printed in-house from ABS plastic, the same material used to make LEGOs, giving Whitmore's team the flexibility to refine designs quickly and push performance forward. The propellant is gaseous oxygen, commonly known as laughing gas, making the system both safe and environmentally friendly while delivering higher performance than traditional cold-gas systems.
"In other words, the rocket is made from LEGOs and powered by laughing gas," said Whitmore. "Although the PSI hybrid gas-generator system was not originally designed as an in-space propulsion system, by the successful completion of this program — under both ambient and vacuum conditions, and across three different test facilities — this 75-mm thrust chamber will be the most highly tested and well-characterized hybrid motor in history."
This project represents more than just a technological achievement — it reflects decades of service, mentorship and a relentless drive to expand the frontiers of aerospace engineering. Throughout his career, Whitmore has guided hundreds of students who have gone on to shape the future of the aerospace industry. His legacy blends cutting-edge innovation with hands-on education, ensuring that the next generation of engineers is prepared to dream boldly and build fearlessly.
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Writer: Madeline Buskirk, madeline.buskirk@usu.edu, 435-797-7512
Contact: Stephen Whitmore, stephen.whitmore@usu.edu