Coupled Navier-Stokes and Direct Simulation Monte Carlo (NS-DSMC) simulations of gas flow in micro-nozzles for various wall thermal conditions and geometrical aspects are presented. Micro-thrusters employed in miniature spacecraft and microsatellites experience substantial changes in wall thermal conditions. This can influence the internal boundary layer development and the exit plume structure of a micro-nozzle. These changes in flow physics differ with the nozzle divergence angle and the proximity of a similar nozzle in the cluster. Continuum solvers often fail to analyze the micro-nozzles operating in vacuum conditions as the flow in micro-nozzles experiences continuum, transitional, and rarefied regimes. Coupled NS-DSMC solver is an effective alternative that can simulate the non-equilibrium effects in a micro-nozzle flow field. A steady solution of the entire flow field has been obtained using a non-linear Harten-Lax-van Leer-Contact (HLLC) scheme based finite volume solver with a higher order slip boundary condition. Continuum breakdown regions are identified based on the gradient-length local (GLL) Knudsen number condition. This initial steady solution on the flow transition boundary is implemented in the DSMC solver as a Dirichlet boundary condition. The present computations are useful in calibrating micro-propulsion controllers to adapt to the substantial momentum changes associated with various nozzle wall thermal conditions and the proximity of similar nozzles in the cluster. © 2019 Elsevier Masson SAS