Mechanical, thermal, and sensitivity properties of plastic bonded explosives (PBX) depend on the type of ingredients in their formulation. Aim of the work is to develop aluminized cast PBX formulations and process conditions by using alternative inert plasticizers to have similar or better properties than PBXN-109 without compromising sensitivity properties. Although very small portion of total production of plasticizers is used for solid rocket propellant and explosive formulations, they play very significant role in that area. Both inert and energetic plasticizers have involved propellant and explosive formulations to improve process parameters, mechanical properties, and even insensitivity properties of them. Isodecyl pelargonate and dioctyl adipate are the most preferred inert plasticizers in polyurethane based thermoset propellant and explosive formulations. In addition to them, diisononyl adipate and diisononyl phthalate were used and screened as inert plasticizer candidates for aluminized cast PBX formulations. Mechanical, thermal, and sensitivity properties of PBX formulations were studied and compared in detail. (C) 2014 Wiley Periodicals, Inc.