AbstractIn this work we investigate the potential application of nano‐aluminum/nitrocellulose mesoparticles as an ingredient for solid composite rocket propellants. The basic strategy is to incorporate nanoaluminum in the form of a micrometer scale particle containing a gas‐generator, to enable easier processing, and potential benefits resulting from reduced sintering prior to combustion. The mesoparticles were made by electrospray and comprised aluminum nanoparticles (50 nm) and nitrocellulose to form micrometer scale particles. In this study, 80 % solids loaded composite propellants (AP/HTPB based) were made with the addition of micrometer sized (2–3 μm) aluminum (10 wt‐%), and compared directly to propellants made by directly substituting aluminum mesoparticles for traditional micrometer sized particles. Propellant burning rate was relatively insensitive for mesoparticles containing between 5–15 wt‐% nitrocellulose. However, direct comparison between a mesoparticle based propellant, to a propellant containing micrometer scale aluminum particles showed burning rates approximately 35 % higher while having a nearly identical burning rate exponent. High speed imaging indicate that propellants using mesoparticles have less agglomeration of particles on the propellant surface.