1) The Dark Star delays were pre-cut to a specific length on an automated remote cutter, and then bonded (not just inserted) into the ejection plug; this prevented some of the issues that Aerotech experienced with hot gasses blowing past the delay and igniting the black powder charge prematurely.

2) Both the propellant and delay formulations were designed by Scott Dixon with a minimum of a 25 year shelf life. The motors should fly well long past the 25 year mark, but there was a conscious effort to formulate with long term aging in mind.

Matt