Manufacturing Techniques

Space power supplies are normally assembled in a controlled environment, class 100,000 or better. During and after assembly, they will be subjected to precision cleaning operations.

In fabricating space power supplies, great reliance is placed on documenting detailed procedures for all manufacturing operations, as well as training and certification of all operators. Quality requirements such as NHB-5300 and MIL-Q-9858A mandate procedures for all manufacturing operations.

The purpose of the procedures is to allow review of the operation, consistency in its application and as a criteria for training.

For a typical hybrid module, approximately 40 procedures may be required. For magnetic component manufacture, approximately 20 procedures may be required. For discrete assembly, approximately 30 procedures may be required. The hybrid procedures are written around MIL-PRF-38534, the magnetic procedures around MIL-STD-981 and the discrete assembly procedures are based on NHB-5300.

The operators performing these procedures are trained (in accordance with a training procedure), tested on their knowledge and ability to perform the procedure, then are certified for that procedure. Outside agencies have cognizance of the certification of procedures as well as instructors, which is renewed at periodic intervals.

The intent of generating all these procedures and methods is that nothing be left to chance or to interpretation. This overcomes part of the learning curve that would otherwise occur with a small unit quantity.