CUSTOM-SHAPED CAST EXPLOSIVE
Tailored Charge. Military-Grade Power.
Key Specs
Explosive Fill Materials
TNT, RDX, custom plastic explosives, composite energetic blends
Casting Capability:
Virtually any 3D shape with tight tolerances
Manufacturing Facility
U.S.-based CNC-integrated design and casting plant
Custom-Shaped Cast Explosives
SWORD Energetics specializes in precision-cast explosive components engineered to meet specific mission profiles. Using high-performance materials like TNT, RDX, plastic explosives, and proprietary energetic blends, we produce complex 3D geometries with exacting tolerances. Our in-house U.S.-based facility integrates CNC machining and advanced casting techniques, allowing us to fabricate custom liners and explosive forms tailored for anti-armor, breaching, demolition, and specialized munitions applications.
We support a full range of liner materials—including copper, tungsten alloys, molybdenum, and aluminum—each selected for its unique performance benefits. Our team works directly with customer-provided SolidWorks, STEP, or IGES CAD files to validate manufacturability, optimize performance, and ensure the highest levels of safety. Every unit undergoes strict quality control with dimensional verification, weight conformity, and full traceability. QA documentation and ballistic test data are available upon request, making SWORD Energetics the trusted choice for precision explosive solutions.
Chemical Properties
The primary energetic materials used in our custom-shaped cast explosives include RDX (Cyclotrimethylenetrinitramine), TNT (Trinitrotoluene), or proprietary composite blends. RDX has the molecular formula C₃H₆N₆O₆ and a molecular weight of 222.12 g/mol, while TNT is characterized by its yellow crystalline appearance and high thermal stability.
In its raw form, RDX appears as a white crystalline powder, whereas TNT is a yellow solid. When cast, both are transformed into dense, uniform explosive charges shaped to customer specifications. RDX has a melting point of approximately 204°C, while TNT melts at 80.35°C. These materials.
Chemical Properties – Custom-Shaped Cast Explosives
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Main Energetic Component(s): RDX (Cyclotrimethylenetrinitramine), TNT (Trinitrotoluene), or custom blend
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Chemical Formula (RDX): C₃H₆N₆O₆
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CAS Number (RDX): 121-82-4
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Molecular Weight (RDX): 222.12 g/mol
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Appearance: White crystalline powder (RDX), yellow solid (TNT); cast into solid form
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Odor: Odorless
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Melting Point: RDX: ~204 °C, TNT: ~80.35 °C
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Boiling Point: Decomposes before boiling
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Solubility in Water: Slight (RDX: ~40 mg/L at 25 °C)
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Density (Cast): ~1.60–1.72 g/cm³ (dependent on formulation)
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Vapor Pressure: Negligible
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Flash Point: Not applicable (thermal decomposition)
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Thermal Stability: Stable under normal storage; decomposes at high temperature
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pH (Aqueous Slurry): Slightly acidic
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Compatibility: Avoid strong acids, bases, and incompatible metals
Handling and Safety Notes
Handle only with trained personnel using appropriate personal protective equipment (PPE).
Store in a cool, dry, well-ventilated, and secure location compliant with applicable explosive storage regulations (e.g., ATF, DoD, UN).
Avoid heat, impact, friction, electrostatic discharge, and open flame.
Use non-sparking tools during handling.
Product is thermally stable under normal conditions but may detonate if exposed to extreme heat or shock.
Disposal should be performed by authorized personnel in accordance with local, national, and international regulations.
Full Safety Data Sheet (SDS), test reports, and lot traceability available upon request.
Parameters
Density (Cast): ~1.60–1.72 g/cm³
Detonation Velocity: ~7,000–8,750 m/s (depending on formulation and confinement)
Heat of Explosion: ~5,000–6,000 kJ/kg
Oxygen Balance: Typically -21% to -55% (m/m) depending on mix
Impact Sensitivity: Moderate (varies with binder and formulation)
Friction Sensitivity: Low to moderate
Brisance: High – suitable for precision penetration and cutting applications
Casting Tolerances: Maintained to ±0.005” for mission-critical geometries
Design Support & Engineering Collaboration
At SWORD Energetics, we offer full-spectrum design support to ensure your explosive components meet exact mission requirements. Our team works directly with customer-supplied CAD files to validate geometry, manufacturability, and performance prior to casting.
We accept the following file formats:
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SolidWorks (.SLDPRT / .SLDASM)
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STEP (.STEP / .STP)
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IGES (.IGS / .IGES)
Our in-house engineers and CNC specialists can assist with:
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Design optimization for explosive performance
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Tolerance validation for shaped charge liners and casings
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Material compatibility reviews (explosives and liner metals)
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Rapid prototyping of charge geometry (non-energetic)
Whether you’re developing a new munition system or refining an existing design, we provide technical insight and precision fabrication capabilities to bring complex shapes from concept to combat-ready.
Impact Sensitivity: Moderate (varies with binder and formulation)
Friction Sensitivity: Low to moderate
Brisance: High – suitable for precision penetration and cutting applications
Casting Tolerances: Maintained to ±0.005” for mission-critical geometries