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Rubicon Space Systems / Plasma Processes, LLC

Location: Huntsville, Alabama | Type: SBIR propulsion company, Plasma Processes subsidiary SST role: GPDM chemical propulsion module supplier (Sprite module) TechPort projects (Plasma Processes): 19 (all SBIR/STTR) | NASA awards: $15.4M+ across 25+ contracts (2001–2026)

Last updated: 2026-04-14 (session 36)

Overview

Plasma Processes, LLC is a Huntsville-based propulsion and advanced materials company operating since at least 2001. In 2022, its propulsion division was rebranded as Rubicon Space Systems to commercialize ASCENT green propellant thrusters. Rubicon/Plasma Processes built the 100 mN ASCENT chemical thruster that flew on Lunar Flashlight and the Sprite chemical propulsion module for GPDM. They also develop 5N, 1N, and 110N ASCENT thrusters for NASA and AFRL.

The company is a textbook SBIR Pipeline archetype — 19 TechPort projects and 25+ USASpending awards over 25 years, sustained almost entirely by NASA SBIR/STTR funding. Unlike VC-backed propulsion startups (Accion, Phase Four), Plasma Processes has no known venture funding and operates as a traditional Huntsville small business contractor.

GPDM Lineage — The Chemical Side

GPDM (155369) uses an ASCENT propellant tank feeding both a chemical thruster (Rubicon Sprite module) and four electrospray thrusters (MIT/Espace). Plasma Processes built the chemical half:

Phase TechPort Project Period TRL Key Deliverable
SBIR Phase I 102218 — Dual Mode Green Monopropellant 2019-08 → 2020-09 1→3 5N ASCENT thruster prototype; 4U module design
SBIR Phase II 113181 — Dual Mode Green Monopropellant 2021-01 → 2023-07 3→6 Flight-design 5N thruster; prototype CubeSat propulsion module
SBIR Phase III USASpending 80NSSC23CA043 ($872K) 2023-05 → 2026-04 — Chemical Propulsion Module for GPDM

Key personnel bridges: - John Dankanich (MSFC) — PM on Phase I [102218] AND iSat PI (91492). This means Dankanich connected the iSat institutional knowledge directly to the Plasma Processes SBIR that became GPDM's chemical module. - Nehemiah Williams (MSFC) — PM on Phase II [113181] AND PM on GPDM [155369]. Project management continuity from SBIR to flight demo. - Tomas Hasanof (Plasma Processes) — PI on both SBIR phases. Company technical lead. - Georgia Tech — partner on both SBIR phases AND GPDM spacecraft integrator. The SSDL partnership predates the SST project.

Confidence: confirmed — TechPort Advanced_To chain [102218] → [113181], USASpending Phase III explicitly references GPDM, personnel overlap verified.

Lunar Flashlight Heritage

Plasma Processes built the 100 mN ASCENT thrusters for JPL's Lunar Flashlight mission (106819):

  • USASpending: 80NSSC20C0005 ($988K, 2019–2022) — "Lunar Flashlight Propulsion System 100 mN Thruster"
  • Flight performance: 3.1 kg propellant throughput, 17 hours accumulated firing time, 65,000+ pulses. The thrusters themselves performed nominally — the mission failure was caused by a 3D-printed propellant manifold obstruction (built by MSFC, not Plasma Processes).
  • GPDM explicitly applied Lunar Flashlight lessons: machined (not 3D-printed) manifold components, additional FOD inspections, multiple propellant filters.

Confidence: confirmed — USASpending contract, Rubicon website, NASA Spinoff article.

Full TechPort Footprint (19 Projects)

Domain Projects Key IDs
ASCENT green propulsion 5 102218, 113181, 93503, 90499, 102378
Rhenium thrust chambers 3 9150, 9712, 102768
Nuclear thermal propulsion 5 18086, 33566, 89817, 103014, 112849
Lunar regolith simulant 2 9605, 9669
Other propulsion 3 18339 (100-lbf non-toxic), 33617 (cryo methane ignition), 102826 (nozzle extension)
Hot structures 1 18225

The breadth is remarkable — propulsion, materials, NTP, ISRU. All 19 projects are SBIR/STTR. The company has sustained a 25-year NASA SBIR pipeline without pivoting to VC or defense production (unlike ExoTerra, which followed the SBIR→SDA→acquisition path).

USASpending Federal Footprint

Total NASA awards: $15.4M+ across 25+ contracts (2001–2026)

Key awards: | Award | Amount | Period | Description | |-------|--------|--------|-------------| | MSFC0200204D ($1.82M) | $1.82M | 2002–2010 | VPS combustion chamber liners | | NNX17CM04C | $1.12M | 2017–2021 | Small satellite launch technology | | 80NSSC20C0005 | $988K | 2019–2022 | Lunar Flashlight 100 mN thruster | | NNX12CA25C | $900K | 2012–2018 | Rhenium bipropellant thrust chambers | | NNX12CA29C | $894K | 2012–2015 | Non-toxic monopropellant RCS | | 80NSSC23CA043 | $872K | 2023–2026 | GPDM chemical propulsion module (Phase III) | | NNM13AD63P | $816K | 2013–2016 | Iridium microthruster SBIR Phase III | | 80NSSC21C0030 | $750K | 2021–2023 | Dual mode green monopropellant (GPDM Phase II) | | 80NSSC20C0198 | $750K | 2020–2025 | Refractory metal uranium nitride NTP fuel | | Multiple × $600-750K | ~$5M | 2003–2020 | NTP, regolith, nozzles, various SBIR Phase II |

AFRL Contracts

Award Amount Period Description
FA930022C6008 $5.53M 2021–2026 Demonstration of Long Life 1N Thrusters with ASCENT and other AF-M315 formulations

Additional NASA Awards (not in session 16)

Award Amount Period Description
80NSSC23CA229 $211.9K 2023–2025 SBIR Phase III — 110N ASCENT Thruster Development
80NSSC21C0012 $367.3K 2021–2025 Multi-use coating for abrasion prevention, wear protection, and lunar dust removal

Updated federal footprint: NASA ~$16M+, AFRL $5.5M+. Total visible: ~$21.5M+ across NASA + AFRL.

Commercial Traction (session 36)

  • "30+ thrusters sold" (Rubicon website/SpaceNews, 2025) — first quantified commercial metric
  • Sprite module delivered to NASA for GPDM integration (SpaceNews confirmed)
  • IEPC-2025-495 paper presented September 2025 in London: "Green Propulsion Dual Mode (GPDM) Path to Flight"
  • Sprite: additively manufactured titanium pressure vessel, single 0.1N (100 mN) ASCENT thruster, 1,200 Ns total impulse (~100 m/s ΔV for 12U CubeSat)
  • Product line now spans: 0.1N (flight-proven, Lunar Flashlight + GPDM), 1N (AFRL qual), 5N (SBIR-developed), 110N (NASA SBIR Phase III)

NTRS Publications (4)

Year Citation Topic
2022 20220009968 Development of ASCENT Propellant Thrusters (Kilcoin, Cavender, Hasanof)
2022 20220010300 Development of ASCENT Propellant Thrusters (presentation)
2022 20220006844 100 mN Green Monopropellant ASCENT Thruster Development (Hasanof)
2013 20140002268 High-Pressure Lightweight Thrusters (Holmes, McKechnie)

Assessment

Archetype: SBIR Pipeline to Production (variant: multi-domain SBIR sustainer)

Unlike ExoTerra (which followed the SBIR→SST→SDA→acquisition path), Plasma Processes has sustained a 25-year SBIR-dependent business model without pivoting to defense production or seeking acquisition. The 2022 Rubicon rebranding suggests commercialization intent, and the ~$6M AFRL contract is the first significant non-NASA production revenue.

What makes this company significant for SST: - Built both the Lunar Flashlight thruster (which worked) and the GPDM Sprite module (pre-flight). The company IS the ASCENT hardware maturation pipeline for small spacecraft. - Dankanich bridge — iSat PI was also Plasma Processes SBIR PM. MSFC propulsion expertise flows through this connection. - ASCENT roadmap dependency — NASA's post-GPDM plans for 5N and 22N ASCENT thrusters run through Rubicon. If GPDM succeeds, Rubicon is positioned as the incumbent ASCENT supplier. - 19 TechPort projects ties with ExoTerra (13 TechPort projects) for deepest NASA SBIR pipeline among SST-adjacent companies.

Session 36 update: Rubicon's trajectory is accelerating. The AFRL 1N contract ($5.53M) is now the largest single award — nearly 3× any NASA award. The "30+ thrusters sold" metric suggests real commercial traction. The 110N SBIR Phase III ($211.9K) opens the door to main-engine-class applications (lunar landers, space stations). The company is no longer purely SBIR-dependent — it's building a product line.

Open question: Will the Rubicon rebranding lead to a defense-prime acquisition (following ExoTerra/Tyvak/BCT pattern), or will it scale as an independent ASCENT propulsion supplier? The AFRL contract + 30+ thruster sales suggest the latter is possible. GPDM flight success (if it launches) would be the critical proof point.