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

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Other metals will work, such as copper powder, zinc powder, potassium permanganate makes a purple flame. ^{[1]
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Also put in a few matches while it dries.
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Put it on the ground and have some fun. ^{[2]
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Method 2

Method 2 of 2:

Signal flare #2

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Shake and turn the container to allow the material to be thoroughly mixed. ^{[3]
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Crank the flame down to a low level. Most propane stoves will produce a 1/4-inch high flame at this level.
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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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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.
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Twist the end of the paper and put the flare in a self-seal plastic bag.

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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.

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

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

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Will the flare shoot into the air?

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Not unless you put a propellant below it.

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Tips

If you want to add color to your flare you can add metallic salts such as magnesium sulfate (Epsom salts) to make it white. Strontium Nitrate to make it red (this can be some-what hard to find.) Barium will burn a pale green. So will borax. Copper sulfate burns a green too. Potassium permanganate burns purple. Look online for some other colors.

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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 :

Potassium nitrate
Powdered sugar
Mason jar or shake tumbler
Propane camp stove
Heavy steel skillet
Safety goggles
Gloves
Cap
Wood strike-anywhere matches
Tissue paper

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How to Make a Signal Flare

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Signal flare #1

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