A layered thermite composite includes alternating layers of metal oxide and reducing metal deposited upon a substrate. A fuzzy interface layer between each metal oxide layer and reducing metal layer includes reducing metal, reducing metal oxide, and metal oxide at least partially intermixed therein. The fuzzy interface layer forms while moving between chambers in a multi-chamber deposition process which minimizes exposure of the reducing metal to oxygen while moving between chambers. The fuzzy interface layer is not expected to grow in thickness after deposition. The combination of the relative thinness of the fuzzy interface layer as well as the presence of reactants as well as reducing metal oxide maintains the sensitivity of the layered thermite structure to mechanical ignition if the structure is used within a primer.

A layered thermite composite includes alternating layers of metal oxide and reducing metal deposited upon a substrate. A fuzzy interface layer between each metal oxide layer and reducing metal layer includes reducing metal, reducing metal oxide, and metal oxide at least partially intermixed therein. The fuzzy interface layer forms while moving between chambers in a multi-chamber deposition process which minimizes exposure of the reducing metal to oxygen while moving between chambers. The fuzzy interface layer is not expected to grow in thickness after deposition. The combination of the relative thinness of the fuzzy interface layer as well as the presence of reactants as well as reducing metal oxide maintains the sensitivity of the layered thermite structure to mechanical ignition if the structure is used within a primer.

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

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