MECHANICAL PROPERTY CONTROL OF FORMABLE ORDERED MICROCOMPOSITE ENERGETICS FOR PRESSURE EXTRUSION 3D-PRINTING

Macropore-Infused Nanocomposite Epoxy Thermosets (MINETs) are hyperuniform three-phase emulsions consisting of continuous jammed-particle, epoxy-resin, and working-fluid phases stabilized by a surfactant, and have tunable mechanical, transport, and combustion properties. Formable Ordered Microcomposite Energetics (FOMEs) are a class of MINETs that incorporate continuous fuel and oxidizer phases, tuned specifically for propellant applications. This study investigates the dependencies of formulation and process parameters on the FOMEs’ pre-cured viscoelastic behavior. Once stable emulsions were cured, the formulation parameters were evaluated for their influence on mechanical and combustion properties. This study also explores the process-structure-property relationship for pressure-extrusion 3D-printing FOMEs, tuning process parameters and feedstock properties to optimize the 3D-printing process. The FOME 3D-printing process is simulated to determine the dependencies of extrusion and shear on pressure, enabling faster experimental iteration and optimizing print speed while maintaining its pore structure. Deriving a FOME-extrusion model, optimal process parameters can be selected with known FOME rheology. This study develops a workflow to inverse-design FOMEs for 3D-printing and modeling suitable process parameters while maintaining control over mechanical properties and burn rate, thereby expanding both manufacturing flexibility and property control.