In this work, the energy characteristics of different propellants were thermodynamically calculated using the Minimum Gibbs free energy method. Based on such calculations and the previous experimental results using the DSC investigations on the thermal decomposition behavior, an optimized propellant formulation was selected. The numerical simulations on the temperature distributions for a prepared miniaturized motor with this formulation were conducted, and the resultant thermal stress and deformation of the thruster array were investigated. In particular, a physical micro model was established, and the effects of combustion parameters on the thermal performance were studied. The results showed that the highest temperature occurred at the boundary of the combustion chamber, where the thermal stress and deformation were the maximum. Furthermore, the thermal stress and deformation of silicon material was smaller than steel, and the thermal stress was the main reason for the destruction of micro-thruster stability. In addition, the maximum thermal deformation was small and had little effects on the thermal stability, whereas the thermal stress was the main reason for the poor thermal stability. (C) 2017 Elsevier Ltd. All rights reserved.