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
