Method of producing solid propellant element

A method of additively manufacturing a solid propellant element, the method comprising:

• heating a nozzle to produce a heated nozzle;
• extruding through the heated nozzle a propellant material that includes a solvent, to form the solid propellant element;
• embedding one or more devices in the propellant element during the extruding;
• wherein the extruding occurs when the heated nozzle is at a temperature that above a boiling point of the solvent and below a decomposition temperature of the propellant material;
• and
• wherein the extruding removes some of the solvent from the propellant material.

A method of additively manufacturing a solid propellant element, the method comprising:

• heating a nozzle to produce a heated nozzle;
• extruding through the heated nozzle a propellant material that includes a solvent, to form the solid propellant element;
• prior to the heating and the extruding, mixing the propellant material, combining together a fuel, the solvent, an oxidizer, and a binder;
• wherein the extruding occurs when the heated nozzle is at a temperature that above a boiling point of the solvent and below a decomposition temperature of the propellant material;
• wherein the extruding removes some of the solvent from the propellant material;
• and
• wherein the mixing includes combining an excess amount of the solvent, beyond that that would be used to form a cast or molded cured propellant element.

A method of additively manufacturing a solid propellant element, the method comprising:

• heating a nozzle to produce a heated nozzle;
• extruding through the heated nozzle a propellant material that includes a solvent, to form the solid propellant element;
• wherein the extruding occurs when the heated nozzle is at a temperature that above a boiling point of the solvent and below a decomposition temperature of the propellant material;
• wherein the extruding removes some of the solvent from the propellant material;
• and
• wherein the extruding includes extruding the propellant material in a partially cured state.