Safety is one of the main conceit's while messing high explosive Many in devices consist of a pentaerythritol ten mini ate (PEEN!) high density column, which is pressed manually in a pneumatic press using a die plunger assembly An accidental in of the pellet while pressing may lead to severe damages to the press and injuries to the operator In this paper, a multi-layer jacket is proposed to be used around the die plunger assembly during pressing to absorb the energy released by PETN. reduce the shock pressure and arrest fragments in case of an accidental initiation/explosion The design is based on the stress strain characteristics of the materials and impedance mismatch principle The material properties such as strength coefficient. strain hardening exponent. sonic velocity and density have been considered for the design Other factors such as availability. machinability. ease of handling have also been considered Theoretical calculations and simulation studies have been carnal out for aluminium alloy (Al2024) - silicone rubber-steel (EN24) combinations The shock pressure levels have come clown from 22 GPa at point of initiation to 0 489 GPa at the last layer of the jacket The theoretical calculations have been verified by simulation studies and validated with an experimental trial