The curing of a glycidyl azide polymer (GAP) with a triisocyanate, Desmodur N-100, was followed by measuring the hardness and viscosity. The thermal behavior of the cured samples were investigated by a differential scanning calorimeter (DSC) and thermal gravimetric analysis (TGA). Curing causes an increase in the glass transition temperature of GAP. The T-g of gumstocks also increases with an increasing NCO/OH ratio while the decomposition temperature remains practically unchanged. The ultimate hardness of the cured samples increases with an increasing NCO/OH ratio. The binder with a NCO/OH ratio of 0.8 was found to provide the most suitable thermal and physical characteristics for composite propellant applications. The increase in the glass transition temperature of gumstocks upon curing can be compensated by using a 1:1 mixture of bis-2,2-dinitropropyl acetal and formal as the plasticizer. The T-g value of gumstocks can be decreased to -46.7 degreesC by adding 25% b.w. of a plasticizer which does not have any significant effect on the decomposition properties of the gumstocks. Furthermore, a remarkable decrease in the ultimate hardness of the gumstocks is achieved upon addition of a plasticizer, while the curing time remains almost unaffected. The addition of dibuthyltin dilaurate as a catalyst reduces the curing time of the gumstocks from 3 weeks to 5-6 days at 60 degreesC. Use of the curing catalyst also results in the hardening of the gumstocks. The decomposition properties of the gumstocks remain practically unchanged while a noticeable increase is observed in the glass transition temperature with an increasing concentration of the catalyst. This can also be compensated by a reverse effect of the plasticizer. The gel time, an important parameter which determines the pot life of a propellant material, can be measured by monitoring the viscosity of the mixture, which shows a sharp increase when gelation starts. The addition of a curing catalyst shortens the gel time remarkably. (C) 2001 John Wiley & Sons, Inc.