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.
Benefit: The development of explosive thermoplastic filaments could facilitate the next wave of explosives additive manufacturing research and development at Capco, the DoD and the DoE. The explosive filament extruder developed during the Phase I will have immediate potential for integration into the DoDs low production volume, small ordnance manufacturing lines. The system also has potential for integration into any DoD production line or research facility that requires 3D printing of explosives.
Keywords: Filament, Filament, Propellant, feedstock, TPE, explosive, Pyrotechnic, ETPE, nitramine
