The cold gas micro-propulsion system can provide low noise and ultra-high accuracy thrust for satellite platforms for space gravitational wave detection, high-precision earth gravity field measurement. In this study, the effect of different needle valve opening ratios on the rarefied flow characteristics of a micro-nozzle in a cold gas micro-propulsion system was investigated based on DSMC method. The special feature of the currently studied micro-nozzle is that it has a section of micro-channel with a large length–diameter ratio up to 4.5. Due to the extremely small needle valve displacement of the nozzle (minimum needle valve displacement up to 1.7 μm), a finely structured mesh was used. The molecular particle and macro flow characteristics inside the micro-nozzle were calculated for the conditions of a needle valve opening ratio from 5% to 98%. The throttling effect of the throat has a significant effect on the rarefied flow in the micro-nozzle; especially under the tiny opening, this effect is more significant. The spatial distribution of continuous flow, transition flow, and free molecular flow in the micro-nozzle varies at different needle valve opening ratios. As the needle valve opening ratio increases, the continuous flow will gradually fill the microfluidic region.

Laser powder bed fusion (L-PBF) enables the integral fabrication of thrust chamber–nozzle and injector assemblies, eliminating some assembly and welding interfaces and reducing structural redundancy. However, under this manufacturing route, as-built geometric deviations act more directly on functional features, creating new challenges for dimensional accuracy and performance stability. To address this issue, this study investigates an additively manufactured 200 N monopropellant thruster and conducts geometric-deviation characterization, deviation–performance mapping, precision allocation, and performance validation. Key forming deviations were characterized using a coordinate measuring machine, industrial CT, micro-focus CT, and confocal microscopy. A first-order geometric deviation–performance mapping model was established through CFD-based sensitivity analysis, and Monte Carlo simulation was used to evaluate performance risk. A priority evaluation system combining the process capability index (Cpk) and performance sensitivity was then developed to guide differentiated finish-machining allowance allocation, CAD model pre-compensation, and process optimization. After two closed-loop iterations, the Monte Carlo-predicted thrust nonconformance probability decreased from 8.5% to 1.2%, and the simulated injection-flow non-uniformity narrowed from ±8.7% to ±4.2%. Cold-flow measurements showed that injection-flow non-uniformity decreased from ±9.3% to ±4.8%. In the rated-condition hot-fire test of the compensated thruster, the measured steady-state thrust deviation was controlled within ±1.5%, while the throat-diameter Cpk increased from 0.56 to 1.45. These results demonstrate that the proposed “inspection–analysis–allocation–compensation” closed-loop method can integrate performance sensitivity with actual manufacturing capability and provide an implementable route for precision-resource allocation and engineering optimization of integrated additively manufactured propulsion components.