The objective of this Statement of Need was to investigate additive manufacturing approaches to propellant design, formulation, and load/assemble/pack-out operations to meet current and future mission requirements for gun propulsion systems across the Department of Defense while reducing the lifecycle environmental impact. Proposals should have addressed the following issues:

• Assess the environmental impact that additive manufacturing processes can impart to propellant formulations, igniters, or combustible cartridge cases that would augment the current propellant design space.
• Address propellant or propulsion-system performance, insensitivity, producibility, and environmental impact across the proposed weapon lifecycle (production, deployment, and demilitarization).
• Address either legacy or novel propellants and/or propulsion systems.

Proposals should have included a plan to conduct a Sustainability Analysis of appropriate proportion to the proposed research and development. Proposals should have established a lifecycle framework that could mature as the technology or process advanced through the acquisition process. This tiered approach aimed to develop and document a minimum data set at each stage of research and development that could be used to make informed decisions and streamline transition to an acquisition program. The Sustainability Analysis may include varying depths of data and information that can inform: the goal and scope of an analysis; the identity and quantity of relevant inputs and outputs to the system; the estimation of life cycle impacts and costs.

Funded projects will appear below as project overviews are posted to the website.

Program Managers, installations, and Warfighters across all services would benefit from sustainable additively manufactured propellants or propulsion systems, particularly those with reduced environmental impact, improved performance and tailorability, reduced sensitivity, and reasonable production costs.

Legacy propellant production and load, assembly and pack would greatly benefit from additive manufacturing techniques that would reduce environmental impact, improve weapon performance, and decrease weapon susceptibility to insensitive munition (IM) threats while maintaining reasonable production and lifecycle costs. Solvent-based gun propellant manufacturing, which is used for all BALL POWDERS®, M14, M31A2, etc., utilizes volatile organic compounds (VOCs) (ethyl ether, ethyl acetate, ethyl alcohol) for processing. In addition to the significant environmental impact of processing with VOCs, which includes hazardous waste disposal, these processing methods have been shown to introduce performance variability. Acetone is often used as a processing solvent and is considered to be VOC exempt; however, when it is contaminated with energetic materials or other gun propellant constituents, it must still be treated as a hazardous waste.

Solventless gun propellant manufacturing (JA2) improves the environmental impact; however, man-in-the-loop hazardous operations and high production costs have significantly stifled transition to propellant production. Additionally, liquid propellant components are known to have migration issues resulting in variable performance and even weakening of combustible cartridge cases. Moreover, where propellants are processed with or without solvent, post-formulation extrusion operations limit the degrees of freedom for propellant geometries due to a fixed cross-sectional area design. The limitations on gross propellant geometries and more refined compositional gradients (deterrents and/or surface coatings) stifle in-flight propellant performance and tailorability.

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. DoD’s Sustainability Analysis uses a life cycle approach to evaluate potential impacts associated with costs, ecosystem quality, human health, and resource availability. 

The cost and time to meet the requirements of this SON are at the discretion of the proposer. Two options are available:

Standard Proposals: These proposals describe a complete research effort. The proposer should incorporate the appropriate time, schedule and cost requirements to accomplish the scope of work proposed. SERDP projects normally run from two to five years in length and vary considerably in cost consistent with the scope of the effort. It is expected that most proposals will fall into this category.

Limited Scope Proposals: Proposers with innovative approaches to the SON that entail high technical risk or have minimal supporting data may submit a Limited Scope Proposal for funding up to $200,000 and approximately one year in duration. Such proposals are eligible for follow-on funding if they result in a successful initial project. The objective of these proposals should be to acquire the data necessary to demonstrate proof-of-concept or reduction of risk that will lead to development of a future Standard Proposal. Proposers should submit Limited Scope Proposals in accordance with the SERDP Core Solicitation instructions and deadlines.