Simulation and experimental study of an integrated static-dynamic mixer for gradient printing of energetic materials

Gradient printing of energetic materials represents a pivotal approach for achieving tunable power output in advanced weapon systems. This study designed an integrated static-dynamic(S-D) mixer to address the requirements for gradient printing, enabling continuous and flexible extrusion of energetic slurry.Numerical simulations employing ANSYS software were conducted to analyze the influence of static mixer geometry on slurry flow behavior, mixing efficiency, and power consumption. An optimized configuration was identified with a mixing unit thickness of 0.5 mm, eight elements, and an aspect ratio of 1. The dynamic mixing mechanism was subsequently refined. Experimental validation utilizing MATLAB-based image processing and fluorescent tracer techniques confirmed favorable flow patterns and mixing homogeneity within the hybrid mixer. This work establishes a viable technical pathway for high uniformity and controlled extrusion of energetic slurries, supporting gradient formation and advanced material fabrication.