In recent years, the application of 3D printing technology in the energetic materials field has proved its ability to innovate traditional charging methods and fabricate complex structures to improve combustion/detonation performance. The melt extrusion technology is the most promising way to fabricate complex structures and multiple components of melt-cast explosives. In this study, a paraffine-based composite was used to substitute melt-cast explosives, and a Design of Experiments approach based on central composite design was adopted to investigate the influence of layer thickness, percent infill, extrusion temperature, and printing velocity on the roughness of printed samples. The results showed that layer thickness and printing velocity could significantly influence the roughness of printed specimens, and no obvious voids or cracks inside the specimens can be detected in computed tomography. In addition, a composite-shaped grain was successfully fabricated via the EAM-D-1 printer, which proved the feasibility of 3D printing melt-cast explosives with complex structures. This work will greatly help to achieve 3D printing melt-cast explosives with complex structures and higher accuracy.
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