New 3D Printable Solid Propellant Binders for Rocket Motors

Solid propellant formulations used for rockets and missiles typically are comprised of a mixture of oxidizer, fuel, and binder.  The Air Force seeks new capability to make solid propellants that can be UV cured so that solid rocket motors manufactured using 3D printing techniques.  The most abundantly used binders are based on hydroxyl-terminated polybutadiene (HTPB), which offers excellent performance in solid propellant compositions.  However, HTPB-based polymers including the polyurethanes made by reacting HTPB with isocyanate derivatives are not suitable for 3D printing as propellant binders. TDA Research Inc. proposes new binder chemistry for use as UV-curable and 3D printable binders in solid propellant formulations.  Our new materials will be scalable, reproducible, safe and have the right performance properties and characteristics for additive manufacturing of solid propellant formulations.  In Phase I, the new ingredients will be prepared, characterized chemically and thermally, and screened for their ability to be UV-cured and 3D printed and formulated with solid propellant oxidizer and fuel ingredients. In Phase II, larger prototypes and continued performance validation will be conducted.  The results obtained will guide a successful program for manufacture of the new solid propellant rocket motors by additive manufacturing, followed by insertion into an Air Force application.