Abstract: A method of manufacturing and optimizing energetic propellant grains includes generating an optimal surface area to mass fraction burned ratio profile for a predetermined solid structure including propellant grains; using the profile as a target function of a topological optimization process to generate a 3D form of a propellant grain; developing a negative of the 3D form of the propellant grain; mixing and densifying the negative with an energetic material in an uncured form in a mixer to create a structure including the energetic material and embedded negative; and solvating the negative from the structure, wherein the negative comprises a 3D propellant grain. The developing of the negative of the 3D form of the propellant grain may occur using a predetermined material in an additive manufacturing process. The negative may be soluble in the predetermined material, and the energetic material may be insoluble in the predetermined material.

Abstract: Porous polymer composites and methods of preparing porous polymer composites are provided herein. In some embodiments, a method for preparing porous polymer composites may include mixing a first polymer with a solvent and a particulate filler to form a first polymer composition, wherein the amount of particulate filler in the first polymer composition is below a mechanical percolation threshold; and removing the solvent from the first polymer composition to concentrate the first polymer and particulate filler into a second polymer composition having a porous structure, wherein the particulate filler concentration in the second polymer composition is increased above the mechanical percolation threshold during solvent removal.

Abstract: A method of manufacturing and optimizing energetic propellant grains includes generating an optimal surface area to mass fraction burned ratio profile for a predetermined solid structure including propellant grains; using the profile as a target function of a topological optimization process to generate a 3D form of a propellant grain; developing a negative of the 3D form of the propellant grain; mixing and densifying the negative with an energetic material in an uncured form in a mixer to create a structure including the energetic material and embedded negative; and solvating the negative from the structure, wherein the negative comprises a 3D propellant grain. The developing of the negative of the 3D form of the propellant grain may occur using a predetermined material in an additive manufacturing process. The negative may be soluble in the predetermined material, and the energetic material may be insoluble in the predetermined material.

Abstract: Porous polymer composites and methods of preparing porous polymer composites are provided herein. In some embodiments, a method for preparing porous polymer composites may include mixing a first polymer with a solvent and a particulate filler to form a first polymer composition, wherein the amount of particulate filler in the first polymer composition is below a mechanical percolation threshold; and removing the solvent from the first polymer composition to concentrate the first polymer and particulate filler into a second polymer composition having a porous structure, wherein the particulate filler concentration in the second polymer composition is increased above the mechanical percolation threshold during solvent removal.