Quoted:
Has anyone ever registered an actual shell? One that could be used over and over? Say a bird bomb that was exceeding the 1/4oz limit.
I see there are a lot of nice reloadable shells on the market now and wondered if anyone ever tried registering the actual shell.
Of course this would have to be fired out of a registered launcher.
I guess the storage issue maybe the problem with doing something like this.
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Yes, by virtue of having very few other spots to retain a serial number post-firing. Reuse, no. BATFE frowns on that whole idea, and your example bird-bomb would be the DD itself, not the case which projected it.
The "storage issue" can be insurmountable, depending on where you live. The required distances are in the orange book, available direct from the BATFE.
Consider Grog's warning on the whole subject, as well... people have been grievously injured trying to make exploding 37/40mm rounds. This warning goes for compositions such as 7:3 flash
and for binary compositions. Both have caused serious injury to the people trying to use them in launched projectiles, and binary compositions aren't friendlier than anything else you'd be likely to look at.
Unless you've got a good handle on what you're doing and are only asking about the legality/storage issues, which may be the case, you really don't want to be screwing around with this stuff right off the bat. Your example bird-bomb is one of the devices which does poorly on launch, and has shredded the (aluminum, in most cases) 40mm barrel on multiple launchers - along with the shooter's hand.
If you're dead-set on this idea, my suggestion is to read up on Grog's forum, read the orange book, see if there are any pyrotechnic clubs in your area, and put in serious study/effort to learn about pyrotechnics. It's really the only route where you can be relatively safe and still achieve your goal.