High-energy insensitive composite explosives have become a key research direction in energetic materials due to their balanced energy output and safety. However, composite particles prepared by traditional methods often have limitations such as low sphericity and poor uniformity. In this paper, the coaxial flow-focusing microdroplet method was used to prepare RDX/F, RDX/F/E, and RDX/E composite particles, with RDX/F/E-P prepared by physical kneading method used as the process control samples to demonstrate the superiority of the process and investigate the effect of the binder formulation on the properties of the samples. Results showed that RDX/F/E has the best sphericity and particle size uniformity, indicating that adjusting the binder system can significantly improve the morphology and particle size distribution of the particles. In addition, the chemical and crystal structures of all samples remained unchanged. Thermal analysis and mechanical sensitivity tests revealed that compared to raw RDX, the apparent activation energy of RDX/F/E increased by 24.75 kJ∙mol−1, and the impact energy threshold and critical friction force were enhanced by 42.5 J and 120 N, respectively, demonstrating excellent thermal and mechanical safety. In ignition tests, the RDX/F/E microspheres produced the clearest and brightest flames, with a significantly shorter burning duration than raw RDX and all other samples, demonstrating that the F2604 and EVA binder system ensures stable combustion while promoting concentrated energy release. This study demonstrates the superiority of the coaxial flow-focusing microdroplet technique, and the proposed F2604-EVA composite binder system provides practical guidance for formulation optimization and performance regulation.
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