Coating processes towards selective laser sintering of energetic material composites

This research aims to contribute to the safe methodology for additive manufacturing (AM) of energetic materials. Coating formulation processes were investigated and evaluated to find a suitable method that may enable selective laser sintering (SLS) as the safe method for fabrication of high explosive (HE) compositions. For safety and convenience reasons, the concept demonstration was conducted using inert explosive simulants with properties quasi-similar to the real HE. Coating processes for simulant RDX-based microparticles by means of PCL and 3,4,5-trimethoxybenzaldehyde (as TNT simulant) are reported. These processes were evaluated for uniformity of coating the HE inert simulant particles with binder materials to facilitate the SLS as the adequate binding and fabrication method. Suspension system and single emulsion methods gave required particle near spherical morphology, size and uniform coating. The suspension process appears to be suitable for the SLS of HE mocks and potential formulation methods for active HE composites. The density is estimated to be comparable with the current HE compositions and plastic bonded explosives (PBXs) such as C4 and PE4, produced from traditional methods. The formulation method developed and understanding of the science behind the processes paves the way toward safe SLS of the active HE compositions and may open avenues for further research and development of munitions of the future.