UV-curing 3D printing of composite energetic materials and its challenges

While 3D printing technologies based on various curing methods like thermal curing, photopolymerization, solvent evaporation molding, and melt cooling have been extensively studied in the field of composite energetic materials (CEMs), recent advancements in multi-material, multi-nozzle, and acoustic resonance techniques are now enabling the fabrication of CEMs with highly complex architectures and novel formulations, including polymer-bonded explosives (PBX), propellants, and pyrotechnics. 3D printing provides a more convenient and reliable approach for the structural design and study of the structure-performance relationship in CEMs, which is challenging to achieve through traditional subtractive or equivalent material manufacturing. UV-curing 3D printing, as a rapid-curing 3D printing method, offers advantages such as superior safety, efficiency, and environmental friendliness over other methods, garnering significant attention in the 3D printing of CEMs. This paper focuses on UV-curing technology and provides a detailed overview of the research progress on various UV-curing 3D printing techniques in the field of CEMs. It also discusses the advantages of 3D printing in the design of structured CEMs charges. Finally, based on the current research status of 3D printing for CEMs, we summarize some existing issues and present our perspectives on future development trends. Although significant progress has been made in the field of composite energetic materials using UV-curing 3D printing techniques, such as stereolithography (SLA), digital light processing (DLP), and UV-assisted direct ink writing (UV-DIW), numerous challenges remain in the areas of formulation preparation, printing processes, and equipment development. The analysis of the key issues currently faced by these technologies, along with a forward-looking perspective on their future development, can provide valuable insights for advancing novel equipment and process technologies. This will ultimately enable high-precision and efficient 3D printing of high-energy and insensitive composite energetic materials, as well as advanced complex charge structures. 1. The application of UV-curing 3D printing in propellants is reviewed. 2. The research progress of different UV-curing 3D printing methods such as DLP, SLA and UV-DIW in the field of composite energetic materials is reviewed. 3. The existing problems and future development trend of 3D printing composite energetic materials are highlighted.