This research investigates techniques for fabricating hybrid rocket fuel grains composed of porous Acrylonitrile-butadiene-styrene impregnated with paraffin wax. The ABS substrate provides mechanical support for the paraffin fuel material and serves as an additional fuel component. The embedded paraffin provides an enhanced regression rate while having no detrimental effect on the thermodynamic burn properties of the fuel grain. Fused Deposition Modeling manufacturing techniques are used to fabricate the ABS substrate that supports the paraffin fuel. Multiple fuel grains with various ABS-to-Paraffin mass ratios were fabricated and burned with nitrous oxide. Analytical predictions for end-to-end motor performance and fuel regression are compared against static test results. Baseline fuel grain regression calculations use an enthalpy balance energy analysis with the material and thermodynamic properties based on the mean paraffin/ABS mass fractions within the fuel grain. In support of these analytical comparisons, a novel method for propagating the fuel port burn surface was developed. In this modeling approach the fuel cross section grid is modeled as an image with white pixels representing the fuel and black pixels representing empty or burned grid cells. A suite of standard MATLAB image-processing techniques is used to regress the fuel grain geometry.
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