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V7I12 Inside a Winner's Circle

DISCLAIMER: Please note that every case is different and these verdicts and settlements, while accurate, do not represent what we may obtain for you in your case.

Revolutionary Reliability Required

Challenge:  Hand assembly of high-reliability contacts was not consistent, reliable, cost effective, or able to keep up with the customer's production demands.  The contact was needed to maintain a perfect electrical connection during high g-force maneuvers in the military's high-performance jets.

Solution:  The assembly is performed in the same die and at the same time as the metal stamping is being producted.  The operation produces a contact where multiple wires were fed into a housing; cut, crimped, and assembled with stamped parts in one progressive die.  Yes, the automation was costly and time consuming.  Several components of the assembly were not high enough quality to be immediately integrated into the stamping process.  The original supplier's components needed to be upgraded to meet specifications and new expectations. 

The end result is high capacity, manufacturing flexibility, and significantly more reliable products that perform in demanding environments.  Was it easy?  No.  But lives depend on the reliability of the electronics within a fighter jet. 

Oh, and the next generation of this product is moving into commercial airlines.  Do you have a project that would benefit from an investigation of alternatives in manufacturing techniques?  Call our engineering hotline -- 1.888.89.STAMP -- to find out.

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