HOUSTON, TX — AeroVance Corporation today announced the successful completion of critical hot-fire validation tests for its proprietary GreenFire™ electric propulsion module. This milestone confirms the system's readiness for integration into the upcoming Phase II deployment of the Project Orion low-Earth orbit (LEO) broadband constellation.

Conducted at AeroVance's dedicated propulsion facility in Las Cruces, New Mexico, the 72-hour endurance test demonstrated performance metrics exceeding initial design requirements. The GreenFire module, a next-generation Hall-effect thruster optimized for high-thrust orbital transfer, achieved a specific impulse improvement of 18% compared to legacy chemical boosters while utilizing non-toxic, eco-friendly propellants.

Unprecedented Efficiency for LEO Constellations

The aerospace industry is rapidly shifting toward sustainable propulsion solutions as satellite constellations grow in scale and complexity. GreenFire represents a paradigm shift in orbital logistics.

"This validation is a massive leap forward for small-satellite logistics," said Elena Rostova, CTO of AeroVance Propulsion. "By combining high specific impulse with rapid cycle times, GreenFire allows operators to deploy heavier payloads with significantly reduced launch mass. It's not just about power; it's about economics and sustainability in the final frontier." 

Key Test Results

  • Specific Impulse (Isp): 2,100 seconds (18% increase over Gen-4 Hall thrusters)
  • Thrust Output: 45 mN nominal, scalable to 60 mN peak
  • Propellant: Non-toxic Xenon-Krypton hybrid mixture
  • Endurance: Zero anomalies over 72-hour continuous burn
  • Mass Savings: Estimated 12% reduction in satellite dry mass

Impact on Project Orion Timeline

The successful validation of GreenFire accelerates the manufacturing timeline for the 200-satellite batch currently in production. AeroVance project management confirms that the propulsion subsystems for the Orion Phase II launch manifest—scheduled for Q4 2025—will now utilize the GreenFire architecture.

This upgrade enhances the constellation's end-of-life deorbiting capabilities, aligning with global space traffic management regulations and AeroVance's commitment to responsible orbital stewardship. Each Orion satellite equipped with GreenFire will possess the delta-V required for autonomous reentry within 25 years of mission completion, well within the 25-year rule mandated by international space agencies.

"AeroVance's commitment to sustainable innovation sets a new standard for the commercial space sector. The GreenFire module is not just a technical achievement; it's a responsible step toward a cleaner orbital environment."

— Marcus Thorne, Director of Space Systems, GlobalComsat Alliance

Production and Integration

Following the completion of qualification testing, AeroVance will begin low-rate initial production (LRIP) of GreenFire units starting May 2025. The company has secured supply chain partnerships for critical components, including advanced ceramics and magnetic confinement rings, ensuring scalable manufacturing capacity.

Integration tests with the Orion satellite bus are scheduled to commence in June 2025 at the AeroVance Texas Assembly Facility. A final review board will convene in August 2025 to authorize flight hardware release.

For more information about the GreenFire propulsion system or to discuss partnership opportunities, please contact the AeroVance Business Development team or visit our Solutions Page.