Hybrid rocket engine (HRE) performance is dependent on fuel/oxidizer selection and fuel grain geometry. A literature review was performed to identify key trends and findings related to the application of the additive manufacturing (AM) of fuel systems for HREs. The effects of complex combustion port geometries, embedded structures, and end-burning systems, along with the use of metallic additives, turbulators, diaphragms, gel-like fuels, powdered fuels, liquid fuels, and liquifying fuels and their impact on regression rates, combustion efficiencies, and/or mechanical strength are thoroughly documented here. In general, the application of AM to HRE fuels can be implemented to increase regression rates and combustion efficiency, and tailor HRE designs. Chemical equilibrium analysis computations were completed to characterize the theoretical performance of HTPB and common AM fuels (ABS, PLA, PC, PMMA, Nylon 6, and a UV-based fuel) with common oxidizers (LOX and N₂O). AM fuels exhibit a similar theoretical performance as the commonly used HTPB fuel, and proper selection of the fuel can yield improved performance and design metrics. Development of AM approaches for HRE fuel design have significantly expanded their design trade space and should enable the competitive application of HREs for future propulsion missions.

Hybrid rockets have distinct advantages over their pure solid or liquid propellant counterparts, and their performance can be improved by inclusion of metal additives. Several metallic additives (micro-Al, micro-Ti, micro-Mg, micro-Zr, nano-Al, nano-B, and Mg-coated nano-B) were selected as potential candidates for hybrid rocket applications and characterized by applicable microscopy techniques. The regression rates and combustion efficiencies of plain HTPB and HTPB loaded with each additive at various concentrations (10%, 20%, and 30% by mass) burning in GOX were evaluated at moderate oxidizer mass fluxes (10–150 kg/m²-s) and pressures ( $\le$ 0.86 MPa, 125 psia). In general, the inclusion of any of the metallic additives led to a reduction in the regression rate and did not significantly change the combustion efficiency. The only exceptions were fuel formulations containing micro-Zr, which yielded a moderate (10–20%) increase in the regression rate at a concentration of 10%. The observed trends were more prevalent at higher oxidizer mass fluxes and higher additive loadings. The reductions in regression rate were attributed to heat transfer blocking effects derived from accumulation of additive particles on the fuel surface layer. These phenomena were especially prevalent in highly loaded fuel formulations containing the nano-additives that exhibited unstable combustion and periodic surface-layer shedding. Zirconium appears to be the best metallic additive available since it can yield the highest theoretical density-specific impulse under the lowest O/F operation ratio without resulting in decrements to overall performance. Notably, combustion efficiency data for all fuel formulations were well correlated to the combustion residence time, and high combustion efficiencies (>95%) were achievable when a satisfactory residence time (~75 ms) was realized.