A method of producing a propellant material element, such as an electrically-operated propellant material, includes extruding a propellant material through a heated nozzle. The nozzle may be heated to a temperature that is above the boiling point of a solvent that is part of the propellant material, yet is below a decomposition temperature of the propellant material. This allows some of the solvent to be driven off during the extruding process, while still preventing initiation of an energy-creating reaction within the material. The heating of the material in the extruding process, and especially the heating of the nozzle that the material is extruded through, may be controlled to remove an amount of solvent that results in the extruded material having desirable properties.

A device may include an electrically-operated propellant or energetic gas-generating material, additively manufactured together with electrodes for producing a reaction in the material. The device may also include a casing that is additively manufactured with the other components. The additive manufacturing may be accomplished by extruding or otherwise depositing raw materials for the different components where desired. The electrodes may be made of a conductive polymer material, for example using an electrically-conductive fill in a polymer.

A system is used for additively manufacturing propellant elements, such as for rocket motors, includes partially curing a propellant mixture before extruding or otherwise dispensing the material, such that the extruded propellant material is deposited on the element in a partially-cured state. The curing process for the partially-cured extruded material may be completed shortly after the material is put into place, for example by the material being heated at or above its cure temperature, such that it finishes curing before it fully cools. The propellant material may be prepared by first mixing together, a fuel, an oxidizer, and a binder, such as in an acoustic mixer. After that mixing a curative may be added to the mixture. The propellant mixture may then be directed to an extruder (or other dispenser), in which the mixture is heated to or above a cure temperature prior to the deposition, and then deposited.

A propellant manufacturing method for manufacturing a propellant including a propellant grain having a first surface on which combustion starts upon ignition and a second surface to be coupled to a wall surface that prevents combustion. The manufacturing method includes placing a portion of first propellant having a first burning rate in a first space containing a first position on the second surface; and placing a portion of second propellant having a second burning rate higher than the first burning rate in a second space containing a second position on the first propellant. The method further includes placing a portion of third propellant having a third burning rate higher than the second burning rate in a third space containing a third position on the first propellant. The method further includes completing the propellant grain by simultaneously hardening the entireties of the first propellant, the second propellant, and the third propellant.

The invention relates to Polymerisable Binders, and Insensitive Munition (IM) energetic materials particularly to non-phthalate IM propellant compositions which are printed by a UV curing additive layer manufacture process. invention there is provided an additive layer deposable energetic composition suitable for use as a propellant comprising the following components in the following relative proportions: component A; from 60% to 95% by weight of a highly energetic filler comprising at least one nitramine compound; and component B: from 5% to 20% by weight of a binder, wherein the binder contains component D a UV curable binder in the range of from 3% to 12% by total weight of the formulation, at least one UV photoinitiator, component C: from 1% to 15% of a plasticiser, the percentages by weight of components A, B, D and C, together with minor additives, if any, adding to 100%.

The invention is directed to a method for the preparation of an energetic material product such as a propellant or explosive charge or grain, wherein said method comprises additive manufacturing comprising co-extrusion of at least two materials to form a multi-layered filament and layer-by-layer deposition of said multi-layered filament, wherein said multi-layered filament comprises a first material layer and a second material layer of which at least one comprises an energetic material. In another aspect, the invention is directed to an apparatus for use in this method, said apparatus comprising a co-extrusion nozzle

The invention relates to an energy-releasing composite material comprising at least one nanoporous material and at least one inorganic oxidant, characterised in that said nanoporous material is a nanoporous carbon material.

The invention relates to a coating method for energetic material (12), in particular in a vacuum. The energetic material (12) is coated by chemical or physical vapor deposition. The coating material (16) is electrically conductive and/or hydrophobic or hydrophilic. The energetic material (12) is shaped as grains and/or pellets and/or is in the form of a powder.

A method for removing a gas from a propellant composition includes providing an uncured propellant composition comprising a bonding agent, energetic particles, and a polymeric binder, and flowing an inert gas through the uncured propellant composition to remove an evolved gas from the uncured propellant composition.

The invention relates to a process for forming a pre-defined recess in a cured or cast explosive composition comprising the steps of: i) providing a female mould, ii) providing a male former, and locating said male former proximate to the female mould to create a gap between said male former and female mould, iii) forming an admixture of a curable/castable explosive composition, charging the gap with the admixture of explosive composition, causing the cure or cast of said curable/castable explosive composition, removing the male former to furnish a cured or cast explosive composition with a pre-defined recess.