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Manufacturing Process Development

 

CAP scientists and engineers have had extensive successful experience in translating highly complex technology to mass production. One example is the US Navy Nulka electronic warfare decoy. The prototype decoys were designed to allow high rate mass production of these highly complex electronic assemblies. Details of the technology remain classified, however the success of the manufacturing and deployment is well known. Key technical issues involved high power microwave devices, antenna systems, power supplies, special orientation technology, and harsh physical environments. The ultimate product was refined to allow high rate manufacturing.

Unique devices to allow secure, high reliability data links for the Mark III data link were designed and qualified by CAP personnel. Mass production was critical to the timely development of this unique system which is now deployed on helicopters, surface ships, and submarines. The manufacturing processes for the key devices involved a wide range of technology ranging from inert environment processing to automated testing.

The non-optical capabilities of the US Navy Type 18 periscopes were enabled by devices designed by CAP personnel. A wide range of materials and process knowledge was applied to allow the mass production of thousands of devices to enable the ESM capability of these essential military systems.

 

Several advanced electronic warfare systems were designed and taken to mass production by CAP personnel. Each involved development of processes and equipment which allowed the transition from laboratory prototypes to mass produced military systems.

 

 

CAP is currently under contract to commercialize a plasma technology which will address a wide variety of applications from water treatment to waste processing. As a final outcome of the contract, CAP is required to establish two mass production facilities, one in the US and one in Europe, to economically manufacture this unique technology.

 

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