[Talisker]

I read that making big boosters isn’t a problem - managing the vibration resonances as it fires is the problem. They can rip the rocket to pieces.

[headstamp 2]

What is its power relative to the Saturn 5?

[TXnMA]

Another challenge is maintaining a consistent burning surface area as the SRP burns away. (An increase in burning area = an uncontrolled increase in internal pressure and thrust.)

Just about the worst defect is burning at the interface between propellant and the casing.

That's why polysulfide rubber-based propellants are literally Vulcanized to their casings -- in huge autoclaves.

It's not called, "rocket science" for no reason... '-)