In solid propellant rocket motors, the design of grain port geometry primarily dictates the motor ballistic performance. The flexibility offered by the spatial variation of the port shape on motor performance is often discounted due to the requirement of complex mandrel shapes along with their associated manufacturing issues coupled with propellant processing constraints. Literature data indicate improvement in motor volumetric loading and stability by planned distribution of burn surface area along motor length. This paper deals with the realization and testing of a subscale motor with central finocyl-based grain geometry. A novel method of casting complex grain shapes in solid rocket motors using the wax mandrel technique is discussed. The wax mandrel preparation, propellant casting procedure, and wax mandrel removal setup are elaborated. Static testing results of the subscale motor with central finocyl port geometry are also presented as proof-of-concept. This work has demonstrated the feasibility of realizing solid rocket motor grains using the wax mandrel technique, which further enables realization of complex grain designs necessary to meet various mission requirements.
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