Engineering Precision: PGC's Approach to Complex Components

Background

PGC has established a strong relationship with a globally recognized customer who specializes in creating sensors and electronics that enhance the safety and efficiency of various manufacturing processes. This customer is renowned for the quality and durability of their products and continually innovates to meet market demands. Due to PGC's proven track record of meeting expectations with their previous orders, the customer had full confidence that our engineers would devise a solution to efficiently and effectively fulfill their request.

Challenge

The customer asked PGC to investigate the possibility of manufacturing a complex, layered component that is essential for creating an electromagnetic interference (EMI) shield included in one of their assemblies. The challenge was to meet the customer's requirement for a specific area of exposed conductive copper, along with an electrically insulating layer covering the rest of the part. As the multiple steps in this process could be costly, it was important to find a cost-effective solution that would meet our customers' needs. To achieve this, PGC application engineers needed to understand the necessary materials and dimensions that would maintain critical edges and tolerances of the part.

Solution

Drawing from their process experience, PGC's application engineers devised a strategy involving blanking and laminating layers while exposing the selected area of conductive copper. Upon realizing that it would be challenging to produce their product precisely as specified, PGC's application engineers created a few prototypes while incrementally changing each until they found one that met the customer's request. The company's frequent communication was pivotal, allowing us to make adjustments that accommodated die-cutting constraints and hand-assembly capabilities.

Results

After a few prototypes and changes to the tolerances, our engineers identified a solution that met the customer’s requirements. The industry experience and the manufacturing skill level of PGC’s application engineers made this a successful order.