13. Modern Approaches to Formulation Design and Production

Changes in technology and understanding are giving new options for the design and manufacture of energetic formulations, whether they are explosives or propellants. It is now possible to approach the problem of matching formulation to desired characteristics in a systematic manner. This approach can cover all aspects from conception to disposal and includes performance optimization. This chapter will discuss and illustrate this: beginning with the use of predictive modeling, based on known properties both of ingredients and of the required output, and also consider its use for the design of novel ingredients to support synthesis research. The options for the physical nature of the ingredients; size, shape, crystal habit, polymorph, etc., and the ways of treating these for use will also be discussed. Composition design follows from this together with the understanding and management of both ingredient and composition characteristics. The ability to design for safety and life will also be discussed as will the need for reduced and managed environmental impact throughout that life. This should include awareness of environmental impact in use and disposal. Finally, the approaches to processing will be considered. The aim is to argue that such an integrated approach is the most cost-effective and productive method of formulating for the future.