A major government defense contractor manufactures a highly specialized gyroscope. This multi-layered component, not much larger than a dime, must be tightly wrapped with a fine wire filament. The thick paper slot liners used to insulate the wire from the sharp edges of the part were limiting the efficiency of the gyroscope. In addition, the epoxy used to laminate the multiple layers of metal was adversely affected by high humidity during the summer months. Consequently, production was brought to a standstill due to high reject rates.
APC engineers were able to deposit an ultra-thin insulating coating to highly specific areas of the gyroscope. Thus eliminating the use of paper slot liners. Specifically, it was possible to obtain exact placement of the coating so that when the edges of the final piece were ground, the coating was not damaged by the process. APC also developed a patented lamination method for assembling the micro-thin layers that was unaffected by high humidity. These patented and proprietary manufacturing techniques have successfully reduced production and labor costs, significantly increased the efficiency of the gyroscope, and virtually eliminated part rejection.
