Pyrotechnics are used in a variety of military applications. Many such pyrotechnic flare compositions contain heavy metal fuel (e.g., strontium, barium) that are used to produce bright colors in the flare, and perchlorate oxidizers. Metals are released with combustion products during normal training operations and will persist on training ranges. Perchlorates have been addressed in the last 20 years and many systems now have alternative formulations that eliminate perchlorate.
Currently, pyrotechnic items such as handheld signals and submarine location markers are single use, single color and require rigorous and costly manufacturing techniques. These techniques and processes have not changed in the last 50 years. Today’s novel pyrotechnics should address the size, weight and power (SWaP) and have multi-function capabilities. DoD needs technologies and manufacturing processes to minimize production time, reduce multi-step processes and reduce solvents and other wastes in flare manufacturing. This could include alternative binders or solvents for use in pyrotechnic formulations or novel mixing and loading technologies that will reduce the required solvent and processing steps for safe manufacturing. In addition, DoD needs to evaluate alternative additive manufacturing processes for pyrotechnics to reduce solvent use and potentially increase current pyrotechnic capability through improved mixing, casting and loading in novel configurations. New manufacturing techniques such as additive manufacturing, new mixing techniques, new color-emitting technology, and tunable “selectable” wavelength technology are available and should be considered to reduce size and weight of pyrotechnics while also providing multi-color capabilities to a single pyrotechnic item.
The Weapons Systems and Platforms Program Area supports development of technologies and processes that are associated with the manufacture, operations, and maintenance of military equipment, weaponry, and munitions. These life cycle stages of a system may impact workers, the environment, and surrounding communities. Increasing the sustainability of these systems offers opportunities to identify and manage these impacts to lower associated life cycle costs and improve mission readiness. The DoD’s Sustainability Analysis uses a life cycle approach to evaluate potential impacts associated with costs, ecosystem quality, human health, and resource availability.