Development of Explosive Feedstock for Commercial-off-the-Shelf (COTS) 3D Printers

Capco will leverage its extensive explosives capabilities to develop flexible thermoplastic filaments consisting of energetic thermoplastic elastomers (ETPEs) mixed with high solid loadings of nitramines, pyrotechnics and strong oxidizers. Capco will also develop energetic filaments consisting of ‘inert’ thermoplastic elastomers (TPEs) loaded with oxidizers for propellant applications. The developed filaments will be designed and tested for compatibility with commercial-off-the-shelf, FDM 3D printing systems. Emphasis will be placed on filament durability and flexibility, extrudability, adhesion, and cohesion. The best performing developed explosive filaments will be utilized for the additive manufacturing of energetic grains during this effort. Optimized filament formulations will be designed with the goal of meeting insensitive munition requirements and comparative testing with currently fielded U.S. Navy formulations. Filaments and test prints comprised of energetic materials will be delivered to NSWC-IH for evaluation at the end of the Phase I effort. Orbital ATK will provide Capco with ETPEs and consultation for this effort.