Advances in Safety Regulation and Performance Optimization of Energetic Materials Driven by Microfluidic and Additive Manufacturing Technologies

The advancement of energetic materials is constrained by challenges in manufacturing safety and precision. Traditional methods often result in irregular morphologies, wide particle size distributions, and significant solvent usage, posing safety and consistency concerns. In contrast, microfluidic technology offers precise control over droplet‐based processes, enabling the fabrication of uniform energetic microspheres with tunable size and morphology. Concurrently, additive manufacturing provides unparalleled design flexibility for constructing three‐dimensional energetic architectures with tailored combustion and mechanical properties. The rapid advancement of these two technologies in the preparation and application of energetic materials underscores the significant value of a timely and systematic review of the latest research progress. This review systematically examines recent progress in both technologies. It first discusses how microsphere characteristics influence safety and performance, emphasizing the role of key microfluidic parameters. It then highlights the advantages of microfluidic encapsulation over conventional methods. Furthermore, the principles and applications of five representative additive manufacturing techniques for energetic materials are analyzed. The synergistic potential of integrating microfluidics with additive manufacturing is also explored from safety and performance perspectives. Finally, current challenges are summarized, and future research directions toward scalable, safe, and functionally integrated manufacturing are outlined.