AbstractThis research is directed towards a better understanding of filled polymer processing in general, and energetic composite solid propellants, in particular. The program established is composed of four stages and isolates batch processing as the technique to be examined. The first stage in the program is a thorough compilation of literally thousands of batch data for meaningful correlation and insight as to important areas within the process. Second is developing the fundamental equations governing the material for highly filled rheological suspensions and solving them numerically (biomodal particle distributions solely are to be considered). Third is the formulation of “model” compounds for experimental verification (this includes the use of perfectly spherical solid particles). Fourth and final is the implementation of this previous work to propellant manufacture. It is desired that from this work, new more economical means of predicting and also enhancing propellant performance can be developed.This paper presents the results of the completion of the first step within this program. A brief discussion of the latter steps is mentioned with respect to their progress. The results to be presented were funded from the College of Enginneering and Mines at the University of Ariz