Advanced muzzle loader ammunition

1. A muzzle loaded ammunition round comprising:

a fixed round comprising a bullet and a consumable cartridge case;

wherein the cartridge case is filled with at least one propellant composition, the propellant composition having a charge weight;

wherein the cartridge case comprises foamed cellulose;

wherein the bullet is commonly engaged to the propellant composition at least via the cartridge case; and

wherein the bullet is positioned within a sabot and the sabot is engaged to the cartridge case.

2. The muzzle loaded ammunition round of claim 1 in which the sabot is constructed at least in part out of a thermoplastic material.

3. A method of manufacturing a muzzle loaded ammunition round comprising a bullet and a consumable cartridge case, the method comprising:

providing a fixed round comprising a bullet and a consumable cartridge case; the cartridge case is filled with at least one propellant composition, the cartridge case is constructed from a consumable material; the bullet is commonly engaged to the propellant composition at least via the cartridge case, the propellant composition has a charge weight, wherein the consumable material is a foamed celluloid;

heating at least one sheet of a foamed celluloid to a predetermined softening temperature;

stretching the at least one sheet about a cylindrical mandrel of a desired diameter of the consumable cartridge case;

using a vacuum to pull the sheet into a desired shape of the consumable cartridge case;

closing a first end of the consumable cartridge case;

filling the consumable cartridge case with at least one propellant composition; and

closing the second end of the consumable cartridge case.

4. The method of claim 3 , further comprising applying pressure to the sheet of a forming die can be used with pressure to finalize the desired shape or dimensions of the cartridge case.

5. The method of claim 3 , wherein a seam is formed where two ends of the sheet of foamed celluloid method and the seam is glued with a cyanoacrylate.

6. A method of manufacturing a muzzle loaded ammunition round comprising a bullet and a consumable cartridge case, the method comprising:

providing a fixed round comprising a bullet and a consumable cartridge case; the cartridge case being filled with at least one propellant composition, the cartridge case constructed from a consumable material; the bullet commonly engaged to the propellant composition at least via the cartridge case, the propellant composition having a charge weight, wherein the consumable material is a foamed celluloid;

extruding foamed celluloid material in a long tube using a thermoplastic extrusion process;

cutting the tube to a desired length of the consumable cartridge case;

closing a first end of the consumable cartridge case;

filling the consumable cartridge case with at least one propellant composition; and

closing the second end of the consumable cartridge case.

7. The method of claim 6 , wherein the first and second ends are closed with small end caps that are attached to the cut cylindrical tube.