In order to improve the energy performance and safety of the explosive, the molding process of melt-casting explosive based on non-TNT with high solid content and density was studied. The temperature field of melt-cast explosive under the condition of natural cooling was established with the ANSYS software though the construction model of the charge shell and finite element model and the analysis for generation and prevention of explosive charge flaws. The high density molding of melt-casting explosive with high solid content based on the matching criterion of the “component-volume-shape size” was realized by the application of some technological control measures such as vacuum, heat insulation and vibration. It was concluded that the quality of charge with no flaws such as stomata, shrinkage cavity and crack in the grain were achieved though the molding process mentioned in above, realizing the high density molding of melt-casting explosive with high solid content.