UV-Assisted Material Extrusion Additive Manufacturing of Double-Base Propellant

Double-base (DB) propellants, renowned for their superior performance and cost-effectiveness, are extensively utilized in both rocketry and artillery applications. During the 3D printing process of double-base propellants, auxiliary solvents play a crucial role in plasticizing the DB propellant mixtures. Consequently, the printed propellants are prone to significant shrinkage and dimensional instability as a result of solvent evaporation post-printing. To address these challenges, we have innovated a UV-assisted material extrusion 3D printing technique that preserves the intended geometries of the DB propellant. The results of our printing trials indicate that incorporating an energetic UV-curable resin as a modifier into the DB propellant paste is highly effective. Ultimately, we successfully fabricated a porous propellant cylinder featuring a periodic woodpile structure. Additionally, the internal structure, mechanical properties, combustion characteristics, and in-barrel ballistic performance of the printed propellants have been thoroughly characterized. Our findings underscore that the UV-assisted material extrusion additive manufacturing process confers exceptional properties to the DB propellant.