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All of the ideas I'm getting from you guys will be grist for the mill. Some of them are really great, and I'll stash them for a solvent-based system. But what's gotten lost in the thread is that this is not a solvent-based system. It's uncured HTPB, which takes (at best) hours to cure. So far, the best idea I've seen might be the "Hershy's Kisses" method, where the sticky stuff is kissed onto a web. The pellets wouldn't be round or cubic, but they'd all be of uniform weight and volume. That might be enough. It would be relatively simple to test. LLoyd
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