The fabrication of energetic compounds on a laboratory and pilot scale requires competence in a range of organic, inorganic and polymer synthetic processes. These processes, which are often accompanied by high reaction heat, rapid reaction kinetics or unstable intermediate products and process conditions, require particularly high process safety. This is the most important design criterium, and is investigated by calorimetry. At the same time, synthetic pathways for new energetic compounds are being developed, and established synthetic routes continually optimised. For fundamental reactions such as nitration nitration, a wide variety of specialist techniques are available. Beside the introduction of special energetic functional groups (e.g. nitro or azido groups) into molecular structures, the fabrication of three-dimensional ring or lattice molecules and special polymer structures (e.g. for thermoplastic elastomers, plasticising agents and binding systems) is another important synthesis aim.

For the safe design and optimisation of hazardous processes, modern processing units based on continuous microreaction technologie are developed and implemented. These units enable more intensive material and heat transfer, as well as the exact control of relevant process parameters (stoichiometry, holding time, temperature etc.). The application of spectroscopic process analysis and calorimetric processes is equally important, both for safety issues and for effective process design. Some of these measurement techniques are developed especially for synthetic processes, and provide important thermokinetic and mechanistic data.