Custom Case Study
The customer’s design required extremely high pulse performance in a small footprint / device volume. The closest existing solution from Vishay was unable to meet the power requirements, while a part that could meet the electrical needs was too large. The customer also required a very cost-effective solution that again precluded the larger device.
Having identified the wire that could achieve the necessary resistance and pulse energy values, it was important to ensure the finished product could withstand the high heat that would be generated, and this was achieved by using a polycrystal alumina with a ceramic core. Vishay tested the selected wire wound around suitable existing ceramic cores that would enable the finished resistor to fit into the limited space available without failure.
Another important consideration was product manufacturability, which had to involve using existing production equipment to ensure costs were minimized.
Prototypes were made and testing demonstrated that the resistor met all of our customer’s requirements and could be produced to meet their overall target cost.
Despite very difficult customer targets in terms of both electrical requirements and cost, Vishay was able to develop a solution quickly by using existing raw materials and component sub-assembly parts. Using manufacturing processes and equipment that were already available also ensured production costs were kept low.
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