SBIR-STTR Award

The united states air force is seeking a simple, low cost method for manufacturing large solid rocket motors. Low cost continuous processing employed in the commercial plastics industry should offer this potential. However, there are unique problems and requirement in manufacturing propellants and commercial continuous processing techniques have not yet found their way into propellant manufacturing. GTA has discoveries and developments relating to the processing of complex composites which address the specific problems presented by continuous processing propellants. Concept feasibility has been demonstrated in a contract funded by Darpa. GTA proposes to demonstrate the technical feasibility of the use of these processes for low cost continuous processing of large solid rocket motors. The GTA technology provides an opportunity for simple, low cost continuous processing of thermoset propellants not possible with other concepts. The principal advantage is the ability to precisely blend all in gradients as a batch in a low shear, non-reactive state. The homogeneously pre-blended material is fed into a continuous processor where minimal work produces a castable slurry. Complex and expensive continuous metering systems are not required. Working time of the ingredients in a reactive state is less than one minute, in a relatively low shear system.

The U.S. Air Force is seeking to reduce the cost of solid rocket motors, particularly large units. Cost savings are possible both in processing techniques and in materials. In the Phase I SBIR program, GTA utilized its pilot plant processing equipment to demonstrate the feasibility of the concept of continuous processing. GTA proposes in Phase II to continue this work focusing on utilization of lower cost binder materials, in particular thermoplastic elastomers (TPE). GTA processing techniques employ new conditions wherein liquids and solids can be intimately blended and mixed without chemical reaction or physical interaction. Utilizing these processes, binder systems can be used which could not be processed with conventional techniques. The proposed Phase II program will investigate new lower cost binders, such as TPE's which, through new processing techniques could meet the desired U.S. Air Force performance specifications.