A method of forming a flexible structure for a rocket motor assembly comprises forming a polysiloxane composition comprising at least two different silicone materials. A preliminary structure is formed from the polysiloxane composition. The preliminary structure is cured to crosslink at least a portion of different polysiloxane chains of the preliminary structure. A flexible structure for a rocket motor assembly, a flexible assembly for a rocket motor assembly, a moveable thrust nozzle assembly for a rocket motor assembly, and a rocket motor assembly are also described.

A hybrid rocket solid fuel grain having a cylindrical shape and defining a center port is additive manufactured from a compound of thermoplastic fuel and passivated nanocomposite aluminum additive. The fuel grain comprises a stack of fused layers, each layer formed as a plurality of fused abutting concentric circular beaded structures arrayed to define a center port. During operation, an oxidizer is introduced along the center port, with combustion occurring along the exposed port wall. Each circular beaded structure defines geometry that increases the surface area available for combustion. As each layer ablates the next abutting layer, exhibiting a similar geometry, is revealed, undergoes a gas phase change, and ablates. This process repeats and persists until oxidizer flow is terminated or the fuel grain material is exhausted. To safely achieve this construction, a fused deposition additive manufacturing apparatus, modified to shield the nanocomposite material from the atmosphere, is used.

A hybrid rocket solid fuel grain having a cylindrical shape and defining a center port is additive manufactured from a compound of thermoplastic fuel and passivated nanocomposite aluminum additive. The fuel grain comprises a stack of fused layers, each layer formed as a plurality of fused abutting concentric circular beaded structures arrayed to define a center port. During operation, an oxidizer is introduced along the center port, with combustion occurring along the exposed port wall. Each circular beaded structure defines geometry that increases the surface area available for combustion. As each layer ablates the next abutting layer, exhibiting a similar geometry, is revealed, undergoes a gas phase change, and ablates. This process repeats and persists until oxidizer flow is terminated or the fuel grain material is exhausted. To safely achieve this construction, a fused deposition additive manufacturing apparatus, modified to shield the nanocomposite material from the atmosphere, is used.

A hybrid rocket solid fuel grain having a cylindrical shape and defining a center port is additive manufactured from a compound of thermoplastic fuel and passivated nanocomposite aluminum additive. The fuel grain comprises a stack of fused layers, each layer formed as a plurality of fused abutting concentric circular beaded structures arrayed to define a center port. During operation, an oxidizer is introduced along the center port, with combustion occurring along the exposed port wall. Each circular beaded structure defines geometry that increases the surface area available for combustion. As each layer ablates the next abutting layer, exhibiting a similar geometry, is revealed, undergoes a gas phase change, and ablates. This process repeats and persists until oxidizer flow is terminated or the fuel grain material is exhausted. To safely achieve this construction, a fused deposition additive manufacturing apparatus, modified to shield the nanocomposite material from the atmosphere, is used.

A hybrid rocket solid fuel grain having a cylindrical shape and defining a center port is additive manufactured from a compound of thermoplastic fuel and passivated nanocomposite aluminum additive. The fuel grain comprises a stack of fused layers, each layer formed as a plurality of fused abutting concentric circular beaded structures arrayed to define a center port. During operation, an oxidizer is introduced along the center port, with combustion occurring along the exposed port wall. Each circular beaded structure defines geometry that increases the surface area available for combustion. As each layer ablates the next abutting layer, exhibiting a similar geometry, is revealed, undergoes a gas phase change, and ablates. This process repeats and persists until oxidizer flow is terminated or the fuel grain material is exhausted. To safely achieve this construction, a fused deposition additive manufacturing apparatus, modified to shield the nanocomposite material from the atmosphere, is used.

A hybrid-like liquid fuel motor (the motor) may include a port surrounded by a wall. Surrounding the wall are a plurality of chambers and segmented walls to separate the chambers. In some instances, a single helix chamber may surround the wall, and may operate similar to that of a segmental chamber. During operation of the motor, gas flows from one end of the port to another end of the port. As the walls surrounding the port begin to disintegrate, liquid fuel within chambers begins to begin to mix with the flow of gas. As the segmented walls between the chambers begin to disintegrate, liquid from the other chambers begin to mix with the flow of gas, creating a metering of the liquid fuel.

A hybrid-like liquid fuel motor (the motor) may include a port surrounded by a wall. Surrounding the wall are a plurality of chambers and segmented walls to separate the chambers. In some instances, a single helix chamber may surround the wall, and may operate similar to that of a segmental chamber. During operation of the motor, gas flows from one end of the port to another end of the port. As the walls surrounding the port begin to disintegrate, liquid fuel within chambers begins to begin to mix with the flow of gas. As the segmented walls between the chambers begin to disintegrate, liquid from the other chambers begin to mix with the flow of gas, creating a metering of the liquid fuel.

Propellant charges or grains having printed layers of two or more energetic materials are described along with methods for preparing and using them.

A solid rocket motor includes a first solid propellant and a second solid propellant at least partially surrounding the first solid propellant. The second solid propellant is resistant to fragment impact and the first solid propellant has a higher impulse than the second solid propellant.

A solid rocket motor includes a first solid propellant and a second solid propellant at least partially surrounding the first solid propellant. The second solid propellant is resistant to fragment impact and the first solid propellant has a higher impulse than the second solid propellant.