Whitepapers

The global supply chain for advanced materials has seen significant growth, particularly for manufacturers that support defense, space exploration, and infrastructure. This class of materials is broad and multidisciplinary, encompassing specialty composites, adhesives, sealants, coatings, lubricants, catalysts, battery slurries and electronic pastes, among others. In a niche category of their own, energetic materials are produced by a relatively small number of producers worldwide, a handful of which are operating at full production scale in the United States. Rising geopolitical tensions have highlighted the need for reliable domestic sources, as government agencies and defense contractors look to local suppliers to quickly strengthen supply chain resilience and shorten lead times. As demand grows, so does the need to expand U.S. manufacturing capability.

But increasing production is not as simple as just mixing larger batches. Energetic formulations are not only mechanically demanding but they need to be processed in a highly cautious manner. How components are mixed can make the difference between a perfectly uniform batch, poor product performance, or worst of all, a catastrophic safety incident. When viscosities exceed one million centipoise, mixing processes become much more challenging. The batch resists flow, creating challenges to agitator exposure, making them prone to entrapping air, and difficult to maintain controlled temperatures. ROSS Double Planetary Mixers (DPMs) are widely used in this sector as formulations scale from laboratory to production. These mixing systems are engineered to operate under extreme mechanical forces, manage uniform dispersion even with high solids loading, and maintain precise control over shear and energy input, all while meeting stringent safety requirements.

Operators who successfully process energetic formulations with a DPM rely on a set of best practices that prioritize controlled material movement, measured energy input, and risk reduction at every stage of mixing.