An insensitive melt cast explosive composition obtained by dissolving an energetic copolyurethane thermoplastic elastomer ("ETPE") in melted trinitrotoluene ("TNT") is disclosed. The resulting ETPE-TNT solution is easy to mix with other ingredients such as nitramines, plasticizers, aluminum and can be processed with the existing melt cast facilities. The energetic solution can be poured into shells and upon cooling to produce a recyclable plastic bonded explosive. Instead of melted TNT, the same process works equally well with melted Octol or melted Composition B to dissolve the ETPE.
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