Novel, Multi-Functional, High Energy Density, Insensitive Polymer Binder Systems for Rapid Manufacturing of Advanced Energetic Materials

Physical Sciences Inc. (PSI) successfully executed a Phase I program that developed and demonstrated novel polymer binder systems that combine high energy density, on-demand curing, and compatibility with ammonium dinitramide oxidizer while retaining critical material properties of conventional energetic materials. The approach capitalized on structural features of conventional polymer systems to provide tailored curing conditions, backbone moieties for good mechanical properties, and enhanced energy density for improved ballistic performance. PSI down-selected binders that are well-suited for development in Phase II based on synthetic accessibility/cost, curing times, gumstock properties and compatibility with energetic formulation ingredients. Specifically, these binders can be used in energetic formulations containing ADN, AP or nitramine compounds. In Phase II, PSI will produce both explosive and propellant formulations binders using both additive manufacturing techniques (3-D printing) and cast curing methodologies. PSI will evaluate the novel formulations using chemical, thermal, mechanical, and ballistic measurements to provide a path for further development in a Phase II Option program. In the Phase II Option, PSI will demonstrate pilot production of energetic test articles and perform extensive performance testing to transition this capability to the DoD and DoD prime contractors for further development in Phase III.