Energetic materials have been produced using manufacturing methods such as casting and milling, which emphasize efficiency and scalability. Although these approaches are well suited for large-scale batch production, they offer limited flexibility for customization—restricting innovation and potentially preventing performance optimization.
This is where new additive manufacturing and 3D printing research enters the equation. Purdue University engineer Monique McClain is developing new methods to control materials’ behaviors throughout the manufacturing process. Professor McClain specializes in the early manufacturing stages such as selecting binders with unique properties to hold energetic particles together and determine how they are mixed.
As an example, a study from Professor McClain looked at adhesion between two polymers with different mechanical properties—think a stiff thermoplastic and a soft elastomer—that have been combined into one structure.
Here is how this can help in manufacturing:
- Enable the two materials to blend and hold together.
- Give more options for controlling behavior.
- Improve safety.
Looking to the future, additive manufacturing will give researchers the freedom to experiment with complex geometries and tune specific properties such as burn rate and blast shape. This is simply one example of research being done in the area.