Process optimization studies were performed for the preparation of the high explosive 3,3 diamino 4,4' azoxyfurazan (DAAF) these process studies were pursued to address issues such as problematic waste generation products particle size, impurities and manufacturability This paper describes the original synthesis method and inherent issues An optimization process was designed to investigate the issues with purity and manufacturability Particle size effects were addressed by adding a recrystallization step to the synthesis Ultimately, a complete solution to all observed issues was found with a new synthesis process, which now allows DAAF to be prepared without any Impurities, with good particle size and without the need for recrystallization Importantly the new synthesis process can be performed in an environmentally friendly manner with the production of non hazardous waste