How to Make a Signal Flare

Last Updated: May 6, 2021

A signal flare is a lighted rocket or smoke flare that alerts someone to your presence. Since the early days of rocket design, military and civilian authorities have counted on smoke and burning-light flares to communicate and save lives. Commercial and military units vary in size and functionality. Smaller units are now readily available for campers and hikers. Since many people prefer to make their own camping and hiking supplies, there is a general interest in both smoke and color-burning flares. While DIY projects to build mercuric oxide-based burning-light flares are prohibited, smoke flares can be easily produced.

Method 1

Method 1 of 2:

Signal flare #1

1
Mix together the potassium nitrate and the aluminum powder. Other metals will work, such as copper powder, zinc powder, potassium permanganate makes a purple flame.^{[1]
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2
Cook the mixture on low heat for awhile and take it off and let it cool in a bucket or something.

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3
Add the bonding agent to the mixture and wait for awhile.
4
Add the mixture while it's about half done drying, put it into your cylinder tube. Also put in a few matches while it dries.
5
Light it up. Put it on the ground and have some fun.^{[2]
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Method 2

Method 2 of 2:

Signal flare #2

1
Mix 1/2 cup powdered sugar and 3/4 cup potassium nitrate in a shake-able container or jar. Shake and turn the container to allow the material to be thoroughly mixed.^{[3]
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2
Light a propane camp stove in a safe, outdoor location. Crank the flame down to a low level. Most propane stoves will produce a 1/4-inch high flame at this level.
3
Place the flare mixture in a heavy skillet and heat it slowly. Stir the mixture constantly. As the flare gum heats it will take on the consistency of melted plastic or chewed gum. Once the material gets to a consistency that allows it to be rolled over in the skillet, it is done.^{[4]
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4
Remove the skillet from the heat and allow the mixture to cool for 30 minutes.
5
Shape the cooled flare material into a long, rectangular bar. Insert three matches -- wood-end first -- into one end of the flare. Push them in until the base of the match head is touching the material.
6
Wrap the flare in tissue paper and provide a 2-inch long paper end. Twist the end of the paper and put the flare in a self-seal plastic bag.

Community Q&A

Question

What bonding agent is used in this? What different chemicals does it contain?

Community Answer

You can use a tablespoon of glycerin for the bonding agent.
Question

Do I need to "cook" or heat up the mixture?

Community Answer

It should be cooked until the mixture has the consistency and color of peanut butter.
Question

Will the flare shoot into the air?

Community Answer

Not unless you put a propellant below it.

Warnings

When you light the flare, keep it well away from the rest of your body. Or just lay it on the ground and leave.

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Things You'll Need

Method 1:

Tube (PVC, cardboard tube, anything will work really)
Powdered aluminum
Potassium nitrate (there's a perchlorate that works better. Either sodium perchlorate or potassium^{[citation needed]})
Bonding agent (flammable glue, or nail polish)

Method 2: