This project focuses on the development of novel 3D printable igniter formulations and additive manufacturing (AM) techniques required to print these materials, to complement the AM propellant development currently underway at the Armament Research, Development and Engineering Center (ARDEC). This would permit embedding the igniters into complex and novel AM propelling charges.

Although there are current efforts underway to generate AM propellants, no work has been performed to produce AM igniters. This is necessary to ensure proper/enhanced ballistic performance of the complete AM propulsion charge. This effort will examine various binders and solid ratios to ensure that BKNO3, an excellent igniter material is amenable to the AM process. At the same time, a printer capable of 3D printing both the igniter and propellant will be developed concurrently. Throughout each step of the development process environmental and safety aspects of the materials and printers will be constantly examined. The final 3D printed propulsion charges will be gun fired in a legacy 30mm cartridge case to demonstrate their performance. In addition to performance testing, ingredients used in this effort will be evaluated for occupational and environmental risks. 

Current manufacturing approaches are inefficient - necessitating additional costs for chemical storage and disposal. 3D printing propulsion charges with embedded igniters are expected to eliminate heavy metals and versus legacy manufacturing methods while reducing manufacturing footprint and costs. The combination of the two technologies (AM propellants and AM igniters) is expected to maximize gun efficiency leading to increased muzzle velocity and range, while not exceeding the operational pressures limits of the gun system. This will push the limits of current gun systems to generate extended range charges that can work in legacy systems. (Anticipated Project Completion-2026)