The objective of this work was to develop and mature a resonant acoustic mixing (RAM) process to reduce the environmental, safety, and occupational health impacts currently observed in the mix-muller manufacturing process of Magnesium/Sodium Nitrate/Epoxy illumination compositions. All RAM compositions were observed to be more homogenous with similar/slightly lower sensitivity than the mix-muller produced materials. Performance testing showed that resonant acoustic mixed material produced similar burn times and similar/increased luminous efficiency to a mix-muller produced composition. In collaboration with Crane Army Ammunition Activity, three M485A2 illumination candles with RAM illumination composition were subjected to standard testing procedures and performed similarly to their mix-muller counterparts. Furthermore, projected benefits of a production-scale RAM process may result in significant increases to overall throughput, labor cost reduction of 61-96%, and a reduction in acetone used for cleanup operations by over 99%.