Abstract: To study the mechanical properties of high solid loaded hydro reactive metal fuel propellant under compression, the uni-axial compression method and needle penetration determination were applied to research the effects of process parameters on the mechanical properties of magnalium hydro-reactive metal fuel propellant under room temperature. The results show that the process parameter is the critical factor to change the mechanical properties since it affects the binder network formation and liquid migration to surface. With the curing parameter increased from 0.9 to 1.0 or pressure-holding time increased from 5 to 25 minutes, the compressive strength, compressive modulus and hardness of propellant would improve rapidly. The mechanical properties would be best when procuring time is 3 hours. The mechanical performance declines with the increase of migration of the binder component in propellant to the surface, which is caused by the increase of mould pressure.