What do scanning electron microscopes and satellites have in common? On the face of things, not much, but after seeing [Zachary Tong]’s latest video on liquid metal ion thrusters, we see that they seem to have a lot more in common than we’d initially thought.

As you’d expect with such a project, there were a lot of false starts and dead ends. [Zach] started with a porous-emitter array design, which uses a sintered glass plate with an array of tiny cones machined into it. The cones are coated in a liquid metal — [Zach] used Galinstan, an alloy of gallium, indium, and tin — and an high voltage is applied between the liquid metal and an extraction electrode. Ideally, the intense electric field causes the metal to ionize at the ultra-sharp tips of the cones and fling off toward the extraction electrode and into the vacuum beyond, generating thrust.

Getting that working was very difficult, enough so that [Zach] gave up and switched to a slot thruster design. This was easier to machine, but alas, no easier to make work. The main problem was taming the high-voltage end of things, which seemed to find more ways to produce unwanted arcs than the desired thrust. This prompted a switch to a capillary emitter design, which uses a fine glass capillary tube to contain the liquid metal. This showed far more promise and allowed [Zach] to infer a thrust by measuring the tiny current created by the ejected ions. At 11.8 μN, it’s not much, but it’s something, and that’s the thing with ion thrusters — over time, they’re very efficient.

To be sure, [Zach]’s efforts here didn’t result in a practical ion thruster, but that wasn’t the point. We suspect the idea here was to explore the real-world applications for his interests in topics like electron beam lithography and microfabrication, and in that, we think he did a bang-up job with this project.