Different composite propellant mixtures have been prepared using ammonium perchlorate, aluminium powder and hydroxyl terminated polybutadiene by varying the percentage of plasticiser and addition of toluene diisocyanate at different temperatures, and studied their different properties such as viscosity build-up, mechanical and ballistic properties and sensitivity. The data on different plasticiser level indicate that on decreasing the plasticiser content, there is a significant enhancement in end of mix viscosity, tensile strength and modulus while elongation decreases drastically. The data on sensitivity of the studied mixtures reveal that on decreasing the percentage of plasticiser, the sensitivity increases, accordingly. Further, the data on the effect of addition of TDI at different temperatures (35-60 degrees C) infer that on increasing the addition temperature of TDI there is a decrease in end of mix viscosity i.e. 800 Pa s at 35 degrees C to 448 Pa s at 60 degrees C. Moreover, there is no effect on mechanical and ballistic properties on higher temperature addition of TDI was observed. (C) 2008 Elsevier B.V. All rights reserved.