Capco’s energetics and explosives design capabilities are as follows:

  • Hydronicallyheated vented powder drying ovens
  • Intrinsically safe vacuum drying ovens
  • FrictionAiredrying ovens
  • Intrinsically safe digital scales (0.2 mg resolution)
  • Pneumatically powered Ross shear blenders (2)
  • 5 liter capacity pneumatically powered 20-quart “Hobart” mixer
  • Proprietary slurry processing and loading equipment
  • Proprietary dry powder processing and loading equipment
  • Full range of separate sieves for fuels and oxidizers
  • RoTapsieve shaker
  • Proprietary modular pneumatic presses, loaders and crimpers with logic control
  • 0.01 mg scale
  • 0-5000 lbload cell
  • additive manufacturing of various energetic materials
  • additive manufacturing of composite energetic grains (4 materials concurrently)
  • mixing and testing of propellants
  • high throughput slurry mixing of particulate energetic materials (nano/ micro / macro)
  • extrusion, spheronizationand pelletizationof energetic materials
  • extrusion, casting and curing of UV Curable propellants, pyrotechnics and explosives
  • FlackTekSpeedMixerDAC 150.1 FVZ-K for rapid, high-shear blending of small pyrotechnic blends
  • QSonicaQ700 800 watts sonicatorwith high throughput Flocelland chiller
  • TA Instruments SDT Q600 simultaneous DSC-TGA with FTIR gas cell
  • MicrotracBluewaveparticle size analyzer
  • ABL Friction sensitivity tester
  • Powder ESD sensitivity tester
  • Cookofftesting
  • Bullet impact testing
  • Drop testing
  • Temperature / humidity / altitude cycling chamber
  • Unholtz-Dickie vibration tester
  • Vibration Research VR5600 shaker and VR9500 controller (sine / random / shock capable)
  • Parr isoperibol/ adiabatic calorimeter
  • Optical microscopes
  • Precision dip coating (mm/min pull rate)
  • 14.5 m3 obscurant test chamber
  • 0.3 m3 obscurant test chamber
  • MWIR/NIR/Vis/UV flame emission spectroscopy
  • Ocean Optics USB4000-UV-Vis spectrometer
  • Ocean Optics USB2000-Vis-NIR spectrometer
  • Nicolet 6700 FTIR with internal and external cells, including diamond ATR
  • UVA spectrum still / video camera (filter + modified sensor)
  • Edgertronichigh speed video camera (up to 17791 fps)
  • Additive manufacturing of composite energetic grains with integral structural elements
  • Process for Slurry Loading of ESD Sensitive Explosive Compositions
  • Thixotropic ZPP Composition for Slurry Loading
  • Ergonomic, ESD safe loading cup and holder for pyrotechnic compositions
  • Modular Loading Booth for Explosives
  • Hydronic cup oven for drying pyrotechnic compositions
  • Particulate Infrared Countermeasure (provisional patent Filed 2009)
  • Metamaterial Chaff (US Patent US 8648306 Awarded 2014)
  • Infrared Countermeasure with Enhanced Spectral Emissivity via Metamaterial Films
  • High Throughput Processing of NanoparticulateEnergetic Materials
  • Boltless Center Bursting Obscurant Grenade
  • Long-burning Non Toxic White Smoke Composition for Grenades and Artillery
  • Ignition Composition with Reduced No-Fire Sensitivity and Improved Ignition Transfer
  • Center-Bursting Expendable UV Countermeasure
  • UV Black Pyrotechnic Smoke Composition for Airborne Expendable Countermeasures
  • Moisture Resistant Ignition Composition for Flares and Fuzes
  • Ballistic Ignition Sensitivity Test Apparatus for Flare Ignition Pellets
  • Exploding Foil Initiator (EFI) Bridge Deposition Using Gas Dynamic Cold Spray
  • Additive manufacturing of composite energetic grains with integral structural elements
  • Process for Slurry Loading of ESD Sensitive Explosive Compositions
  • Thixotropic ZPP Composition for Slurry Loading
  • Ergonomic, ESD safe loading cup and holder for pyrotechnic compositions
  • Modular Loading Booth for Explosives
  • Hydronic cup oven for drying pyrotechnic compositions
  • Particulate Infrared Countermeasure (provisional patent Filed 2009)
  • Metamaterial Chaff (US Patent US 8648306 Awarded 2014)
  • Infrared Countermeasure with Enhanced Spectral Emissivity via Metamaterial Films
  • High Throughput Processing of NanoparticulateEnergetic Materials
  • Boltless Center Bursting Obscurant Grenade
  • Long-burning Non Toxic White Smoke Composition for Grenades and Artillery
  • Ignition Composition with Reduced No-Fire Sensitivity and Improved Ignition Transfer
  • Center-Bursting Expendable UV Countermeasure
  • UV Black Pyrotechnic Smoke Composition for Airborne Expendable Countermeasures
  • Moisture Resistant Ignition Composition for Flares and Fuzes
  • Ballistic Ignition Sensitivity Test Apparatus for Flare Ignition Pellets
  • Exploding Foil Initiator (EFI) Bridge Deposition Using Gas Dynamic Cold Spray
  • Biocidal smoke formulations for bio-agent defeat
  • UV curable propellant / explosive formulations for 3D printing
  • Methods for 3D printing double base propellants
  • 3D printing algorithms for viscous materials
  • Simultaneous co-printing of multiple energetic materials
  • Software workflows for the generation of functionally graded geometries for 3D printed propellants and explosives
  • Closed Loop Vision Control Algorithm for 3D Printing
  • Continuous Process for 3D Printing of Energetic Materials
  • Real-Time Measurement of Energetic Material Processing Parameters Using Terahertz Spectroscopy and/or Terahertz Pulsed Imaging
  • Ultra-high product reliability <1 failure per 5,000,000
  • Design of high volume energetic device manufacturing (>10,000 parts/day)
  • Vertical integration, from marching bodies and glass flow to final product testing
  • Extensive product design and improvement experience
  • Glass to metal sealing processes:
  • Hayes Model LAC 6” Belt Furnace
  • Hayes Model LAC 18” Belt Furnace
  • Rates up to 6,000 parts/hour
  • Temperatures up to 2,000 deg. F
  • Nitrogen/Hydrogen atmosphere
  • Bridgewire installation and welding processes:
  • Micro-wire resistance welding .0001”-.005” diameter wire
  • Soldering of Ni-Cr and platinum bridgewires
  • Circuit board assembly
  • Installation and soldering of thru-hole and SMTcomponents
  • Hand soldering
  • Robotic soldering
  • IR reflow soldering
  • Hot air solder reflow
  • Silk screen/stencil solder paste application
  • Robotic solder paste application
  • Had solder paste application
  • Soldering of high mass components
  • Soldering of nickel plated components
  • Robotic epoxy application
  • 11 gantry style three axis epoxy robots
  • Multiple fixed position forth axis capability
  • One, two and four head epoxy dispensers
  • Marking and engraving
  • Pad transfer printing
  • Silkscreen printing
  • Laser engraving
  • Stamping
  • Laser welding
  • Amada Miyachi
  • 150 Watt
  • 2 axis plus rotary axis
  • Full real-time pulse control
  • High volume pressing, operations:
  • 12 Capco designed semi-automated universal tray operation presses
  • Forces up to 4,000 lb
  • Pressing and staking circuit boards
  • Pressing headers
  • Crimping
  • Staking electronic components
  • Stamping part number/nomenclature
  • Custom designed presses
  • Facilities
  • 3000 square foot explosives manufacturing / assembly area with humidity control, conductive flooring and intrinsically safe electrical fixtures
  • Certified laboratory, production, storage and test areas for class 1.1, 1.3 and 1.4 explosive materials
  • (1) 1.1 and (2) 1.3 explosives storage magazines
  • Loading bays with grounded, conductive work surfaces and ESD Lexan safety shields