The hybrid propulsion performed with paraffin waxes exhibits most attractive capabilities compared to solid or liquid engines, e.g., throttleability and re-ignition, alongside higher regression rates compared to the conventional hydroxyl terminated polybutadiene (HTPB) hybrid fuel. This is because the paraffin wax forms a thin and hydro-dynamically unstable liquid layer, and then enhances the regression rate with the entrainment of droplets from the liquid-gas interface. Nevertheless, some critical open points on the manufacturing of the paraffin fuel grains still persist, because the paraffin wax exhibits high shrinkage during the solidification phase, leading to the formation of cavities, cracks and internal rips, which may be detrimental to the mechanical properties and the structural integrity of the fuel grain. In this context, this paper deals with a wide calorimetric, thermo-mechanical and physical characterization of the paraffin wax selected to manufacture the hybrid rocket engines (HRE) fuel grain, in order to gain a thorough knowledge of the material necessary to avoid the formation of critical defects. Several manufacturing methods were investigated, and it was found that only laboratory scale processes, based on the use of a heated circular mould-piston apparatus, are able to avoid the formation of critical defects, with the application of both high temperature and pressure. Keywords: Paraffin wax, Hybrid rockets, Manufacturing, SASOL® 0907, Regression rate
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