The present invention discloses a process for the on-demand production of small quantities of lead azide. First, a metered quantity of sodium azide solution and a metered quantity of a solution of a lead salt sufficient to react with the sodium azide are introduced into a T-mixer or Y-mixer. Then, the sodium azide and lead salt solutions are conveyed into a static mixer and the azide and lead compounds are permitted to react together, forming insoluble crystals of lead azide as a slurry in an aqueous medium. The lead azide crystals are then separated from the aqueous medium. The process is carried out within an explosion-proof chamber.