Army Advances Copper-Based Replacement for Lead Azide

Researchers have progressed in developing DBX-1 to replace lead azide in military explosive initiators, a compound used since World War I.

Updated on Nov. 4, 2026 in Chemistry

Isometric editorial illustration of an automated dispensing rig releasing dark teal slurry into a row of brass-colored casings on a steel platform. — The Army is advancing DBX-1, a copper-based compound designed to replace lead azide in military explosive initiators, with a full-scale pilot plant expected by early 2028. AI Illustration. Upload story photo >

Army researchers have advanced the development of DBX-1, a copper-based compound designed to replace lead azide in explosive initiators. The Army expects a full-scale pilot production plant to be ready by early 2028 or sooner.

Why it matters

Lead azide has long been used in military munitions worldwide and carries health and safety risks from its toxic composition and fumes. Replacing it with a less hazardous alternative addresses those concerns for military and production settings.

DBX-1 has been successfully used in the M55 and C70 detonators, following years of testing in grenade and artillery fuses and primers. Efforts to replace lead azide date back to 2014, with the pilot production plant targeted for early 2028 or sooner.

The players

U.S. Army

The U.S. Army is the military branch responsible for developing and fielding munitions and explosive initiators.

Armaments Center

The Armaments Center, based in New Jersey, is the Army facility that conducts research and development on weapons and munitions technologies.

The details

Engineers developed automated equipment that loads a wet slurry of DBX-1 into explosive initiators, addressing earlier difficulties in producing the compound in large quantities and flowing it consistently into detonator components. The progress came despite delays brought on by funding challenges.

2014: Researchers first identified obstacles to replacing lead azide.
Monday, November 2, 2026: Command issued a statement on DBX-1 progress.
Early 2028: Full-scale DBX-1 pilot production plant expected to be ready.

The Big Picture

Lead azide, introduced by Germany for military munitions during World War I, has been the standard primary explosive in initiators for over a century. The DBX-1 program represents a deliberate effort to replace that legacy compound with a copper-based alternative that avoids its toxic composition.

The DBX-1 compound would replace lead azide in military initiators, reducing exposure to toxic fumes for those who handle and produce munitions. The timeline for pilot production extends to early 2028, so widespread fielding remains years away.

The takeaway

Replacing toxic legacy materials in critical military components can be achieved, but it often requires years of testing and funding to reach production scale.