Abstract: A method of fabrication of expandable polystyrene plastic ignition contai is disclosed which yields an electric squib case and an ignitor charge case which can be easily loaded with a pyrotechnic charge and an ignitor charge respectively, and when in combination, serves as the ignitor system for a high length to diameter flight motor.The method of fabrication employs expandable polystyrene beads in a first predetermined amount of polystyrene beads which are first pre-expanded to about three times their original size. A second predetermined amount of expandable polystyrene beads are combined with the pre-expanded beads; the combined beads are added to a mold of the desired shape; and the mold is placed in a steam chamber to expand the combined beads to form either the squib case or ignitor charge case.

Abstract: A contoured configured detonating cord and detonator is incorporated into a ember during manufacture thereof. The member may be a rocket motor which is disposed to be broken into small fragments over inhabited areas subsequent to separation of the motor from the warhead. Separation permits the warhead to fly to the target without excessive drag and fragmenting the motor prevents large pieces from falling on the inhabitants. The detonating cord is contoured to the configuration of the motor to prevent stress risers from occurring and thereby weakening the motor structure.