Structural regulation is of great significance for improving the comprehensive performance of energetic materials (EMs). The structural regulation and properties of EMs were summarized. For single-component EMs, particle size control focuses on quality consistency and industrial scalability, morphology modification mainly improves sphericity through monomers or aggregates and explores the possibility of layered energetic materials in improving mechanical properties, and polycrystalline regulation suppresses metastable phases and explores novel crystalline forms using simulation-guided design. Composite EMs (CEMs) employ core–shell structures to balance safety with performance via advanced coating materials, cocrystal engineering to tailor energy release through intermolecular interactions, and lattice strain modulation, and mixing structures integrates component advantages while enhancing the reaction efficiency. Future directions emphasize computational simulations and novel fabrication methods to guide the rational design and precise preparation of next-generation EMs with specific functions.

As a typical high-energy-density material, the sensitivity of CL-20 severely limits its application in explosives and propellants. Adjusting its structure at the microscopic level can effectively solve such problems. In this study, a microfluidic recrystallization technique was used to prepare ε-CL-20 with three different particle sizes, with narrow particle size distributions (D₅₀ = 2.77 μm, 17.22 μm and 50.35 μm). The prepared samples had fewer surface defects compared to the raw material. As the particle size decreased, the density of CL-20 increased and its impact sensitivity was significantly reduced. The activation energy of the CL-20 prepared using microfluidic technology increased with increases in particle size. Laser ignition experiments revealed that smaller CL-20 particles had the highest energy release efficiency, while larger particles exhibited a higher energy density and more stable energy release. The combustion performance and safety of CL-20 can be effectively improved by improving the crystal size distribution and surface morphology. Controllable preparation of multiple particle sizes of CL-20 was achieved using microfluidic recrystallization technology, which provides a reference for the preparation of multiple particle sizes of other energetic materials.

In order to study the curing process of branched polyazide glycidyl ether (BGAP) binder and its propellant slurry at 50 to 70 °C, the rheological properties of BGAP binder and its propellant slurry were studied by chemical rheology. The results show that the viscosity coefficient of the uncured BGAP decreases gradually when the temperature increases, and when the plasticization ratio is 1.1, the viscosity coefficient of BGAP decreases first and then remains unchanged. After adding the curing agent, the chemical rheology method can be used to calculate whether the BGAP curing system still conforms to the power-law equation in a short time. The kinetic equation of the curing reaction, expressed by apparent viscosity, is deduced from the double Arrhenius equation, which can be expressed by η(T,t) = 10.16 exp (−1.72/T) exp [17.27 t exp (−5.21/T)]. After using BGAP as the adhesive to make a propellant slurry with a liquid material component of 25%, the effect of the particle size of Al powder in the solid filler component on the curing process of the slurry was studied, and the 200 nm Al powder could not be made into a slurry under this formulation. The curing kinetics equations of the slurry with Al powder particle sizes of 5 μm, 15 μm, and 29 μm under this formula were obtained by measuring the viscosity of the slurry over time at 50–70 °C. The results showed that the smaller the Al powder particle size, the lower the viscous flow activation energy of the slurry and the higher the curing reaction activation energy.