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Projects Unlimited, Inc.

Aerospace and Electronics Division

As a certified ISO-9001 / AS9100 Small Business, Projects Unlimited, Inc. is a proven aerospace contract manufacturer with the capability of taking your product from concept to production in the shortest possible time. Our full service aerospace contract manufacturing capabilities help you become a more profitable company. From prototype to full-volume production, strengthened by preferred supplier status from several prime contractors, Projects Unlimited is there with the equipment, expertise, and commitment to make it happen. With nearly 60 years in the aerospace and electronics industry, our Projects Unlimited family has grown to over 120 people. The space we occupy is a brand new, state of the art facility with 67,000 square feet configured specifically for high performance electronic manufacturing.

Aerospace and Electronics -Products

Printed Circuit Board Assemblies

Projects Unlimited produces a wide variety of circuit board assemblies using the latest technologies and equipment. We concentrate on our niche markets, focusing on high mix, low to medium volumes that require high reliability in a challenging environment. This includes: Conformal and parylene coating BGA placement Fine pitch SMT Surface mount, through-hole and mixed technologies Through the use of work cells, which allows us flexibility, we can apply our manufacturing processes to accommodate your needs, whether it be in the development of your prototypes or full-up production runs. Cables and Harnesses Projects Unlimited, Inc. fully supports after-market requirements for missile motor firing cables for the F/15, F/16 and F/18 platforms and is the sole source supplier for the Harpoon weapons system cable assemblies. We specialize in the production of high-performance cable assemblies, wiring harnesses and interconnect systems that are built to function in the harshest conditions. Our processes and capabilities also include: Use of flex circuits Compression molding Encapsulation/Potting Wire prep

Military and Commercial

Projects Unlimited, Inc. is a leader in the manufacture of anti-skid control boxes for brake control systems. Working in conjunction with a first tier supplier, the anti-skid control boxes we manufacture are used on a wide variety of aircraft ranging from small business jets to some of the world’s major airlines and aircraft manufacturers in both military and commercial applications. Projects Unlimited Repair and Overhaul is an Air Agency FAA certified repair station that provides maintenance and upgrades to these box assemblies which in turn, extends the life of this equipment as long as it remains airworthy. These systems and their related components deliver high value as a result of advanced design, skilled engineering & efficient production.

De-Icing Equipment

Projects Unlimited is proud to be on the platforms of both the V-22 and Kaman helicopters, providing completely integrated, high level electronic and electro-mechanical de-icing equipment, each requiring electronic assemblies that must be manufactured with a high degree of reliability, and perform in very harsh environments. From design to subassembly to final assembly, we are solutions-oriented. Projects Unlimited can be your manufacturing partner, whether you need circuit board assemblies, which may require conformal or parylene coating to cables or fully assembled boxes. We have the design engineering resources to take your requirements from concept, through qualification testing, to full-up production.

Electronic Subassemblies for Robotics

As a supplier to a major robot manufacturer, Projects Unlimited, Inc. played an integral part in the development and production of the electronic circuitry in a lightweight robot designed to conduct explosive ordnance disposal (HAZMAT, search-and-surveillance, hostage rescue, and other vital law enforcement tasks for Bomb Squads, SWAT teams, military units, and other authorities seeking to meet the security challenges of the 21st century.) With its compact profile and patented mobility platform, this robot can operate with confidence on the toughest terrain - from the stairs, curbs, and rubble of urban terrain to the rocks, sand, and mud of battlefield environments. Our engineering experience, flexible manufacturing and competitive pricing enabled us to meet our customer’s requirements for a complex, high reliability product.

Aerospace and Electronics - Manufacturing

Our manufacturing processes are pivotal in the success of our company. We are a flexible, multi-product environment with the capability of building small prototype builds as well as moderate volume sustained production. Our production operation is well capitalized providing high efficiency from circuit cards through final assembly and test.

Each build is performed using configuration managed drawings and work instructions. Each employee in the manufacturing area views the most up-to-date drawings and specifications electronically via individual laptop computers. All materials are monitored via a facility wide ERP System. The facility is totally air-conditioned and heated with humidity controlled systems in place. ESD protection is provided at all work cells and a conductive floor is installed throughout the manufacturing plant. Projects Unlimited is completely compliant with MIL-STD-1686 Electrostatic Discharge Control Program For Protection of Electrical and Electronic Parts and Assemblies.

Throughhole and Wavesolder

Universal's VCD Sequencer/Inserter with a 60-station module meets the challenges of just-in-time circuit assembly by combining sequencing and inserting of axial leaded components into one continuous process. The unit's variable center distance insertion head provides insertion rates up to 15,000 components per hour, and the dual lead sensing feature verifies insertion of both component leads.

Nu/Era’s wave soldering machine offers the ability to control the wave soldering process with precision accuracy. The Nu/Era MP can store an infinite number of soldering profiles making it an ideal machine to run many different boards. It is also great for sensitive processes that require variables to be within strict limits.

Surface Mount and Reflow

Projects Unlimited has the ability to handle PCBs of any shape and size– from small boards to giant backplanes – a key to the flexibility of our production line. With special handling units or odd and large size boards we are prepared for whatever shape, size, thickness and weight requirements that meet your needs.

The new Model 1700EXL demonstrates Heller's leadership in the marketplace. We provide the most advanced reflow technology for your surface mount assembly line, while combining a more robust system with unmatched versatility and engineering expertise. The 1700EXL- from Heller's newest generation of reflow ovens- provides 25% higher airflow for enhanced temperature uniformity, repeatability and high-load handling. The 1700EXL features Heller's new, enlarged heating tunnel and baffle-free design, for six-sigma consistency, zone-to-zone and oven-to-oven. It also provides more flexibility in board handling, more robust construction and a more streamlined appearance.

Semiautomatic / Hand

CS-400E semi-automatic insertion machine retains all the features which have become recognized benchmarks for cut and clinch machines: ergonomic design, inward and outward lead clinching, miniature cutter footprint, quick and easy set-up, rugged construction and extremely reliable operation. In addition, the CS-400E features the ULTRA CLINCH mechanism which allows the user to program the ideal lead length and clinch angle for each and every component.

BGA X-Ray

As integrated circuit technology miniaturizes and increases in complexity, sophisticated testing and rework equipment becomes essential to the fabrication of quality products. At Projects Unlimited, we incorporate a state-of-the-art X-ray examination system. It provides our inspectors with the ability to analyze solder joints and bonds inside advanced IC packages such as BGAs, within which visual inspection is impossible. Real time Micro Focus X-Ray Equipment can be used on populated and unpopulated PCB's as well as individual components by inspection of the following:

The system features high magnification, meaning the smallest detail can be identified and includes an auto BGA inspection process that consists of short circuit analysis, void calculations, ball count, ball alignment and ball size.

Replacement Capacity

The Freedom 3000 uses custom Windows based control software that incorporates features available only on the most advanced reflow soldering ovens. Control of process, through thermal profiling and editing of heating parameters, is completely at our fingertips. As a result, thermal processing of advanced components is accomplished repeatably from thin “low-mass” PCB’s to large “high-mass” PCBs up to 20” x 20” (50.8 cm x 50.8 cm).

The Freedom Series standard powerful top and bottom heating system applies precise quantities of forced convective energy directly to the component and board. Any combination of gas velocity, temperature and heater height can be used to adjust the heating rate. For “high-mass” assemblies, our Honeycomb IR bottom-side pre-heater is ideal. Its large surface area and ultrahigh heat transfer coefficient provide the additional horsepower needed for rapid soldering while maintaining decreased temperature deltas, thus preventing board warp.

Aerospace and Electronics - Quality

Projects Unlimited, Inc. has held ISO 9001 Certification since 1994. By adopting the philosophy early on that aerospace companies needed to implement the discipline demanded by ISO in order to provide easy interface of it’s services to customers who were evolving from parts manufacturers to systems integrators. This process and philosophy has continued on with our attainment of ISO 9001:2000 and AS9100 status.

By controlling, reviewing and planning each job, the materials procured, the assembly and process control methods as well as product inspection and test requirements, each product manufactured will comply with the customers requirements.

Our workmanship criteria is in strict compliance with ANSI/EIA J-STD-001 and EIA/IPC-A-610 for all manufacturing assembly operations and is implemented as Class 3 – High Performance Electronic Products.

Quality Policy Statement

“The mission of Projects Unlimited, Inc. is to be a growth oriented world class provider of quality products and services designed to satisfy the demanding requirements of our customers, consistent with an acceptable return, to ensure an “unlimited” future for our stakeholders.”

Workmanship

In order to be a World Class company, we must satisfy our customer’s exacting demands. To accomplish this, we must continually improve everything we do. Continuous Improvement is not a program, rather, it is a way of life. We strive to educate everyone in our organization on development of methods, and implement the concept of Continuous Improvement throughout our company. Every individual has a responsibility to embrace the program and to utilize its elements such a teaming, problem solving and statistical process control (SPC) whenever practical. By engaging in Continuous Improvement and applying its various tools and elements, we will live a Total Quality philosophy in everything we do, allowing us to accomplish our mission.

Projects Unlimited, Inc. complies with all requirements for Soldered Electrical and Electronic assemblies–PC/EIA J-STD-001C.
Acceptability criteria of Electronic Assemblies–IPC-A-610C.
Projects Unlimited, Inc. complies with all requirements for ESD Program for Protection of Electronic parts, Assemblies and Equipment.

Certifications

Engineering Design

Projects Unlimited is a world class, ISO 9001 and SAE AS9100 certified design and manufacturing facility that utilizes the latest vision aided, computer controlled, surface-mount assembly equipment and IR convection reflow and wave solder equipment.

Additionally, Projects Unlimited routinely designs equipment for and performs the following:

Environmental testing - ESS, HALT/HASS, classical shock, sine and random vibration.
Cable & Harness testing - Circuit Analyzer Testing.
CCA ICT - In-Circuit Testing
ATP Functional Testing - manual & fully automated functional CCA and (LRU) box level test systems.
Projects Unlimited’s Engineering and Sales personnel have developed a close association with our aerospace customers that has resulted in empowered teams that have successfully resolved previous design, cost, manufacturability, and component sourcing issues for products.
Projects Unlimited has, over the years, designed and manufactured numerous state-of-the-art commercial and military aerospace electronic devices for a variety of applications.
Many of these electronic assemblies and devices are used in commercial and military aircraft and related aircraft applications and have been Environmentally Qualified and Performance Verified by First Article Testing, MIL-STD-810, MIL-STD-461, MIL-STD-704, RTCA-DO-160, and SAE AS9100 methods to insure that they will perform their intended function while meeting all intended design specifications without compromising performance or safety.
Projects Unlimited is also an FAA approved repair depot and has successfully completed and qualified aviation designs resulting in obtaining Supplemental Type Certificates (STC) and Part Manufacturing Authority (PMAs).

Design Engineering Responsibilities

Software Design Tools

Cadence Design Systems, Inc.
"OrCad” Schematic Capture & PWB Layout"
“Pspice A/D” Analog & Digital Circuit Simulation"
AutoDesk, Inc.
"AutoDesk Inventor Professional” Computer Aided Design & Drafting"
Wyse Software Solutions, Inc.
"GerbTool” PWB Gerber Data Viewer and Editor"
Relex Software Corporation
"Visual Reliability Prediction Analysis"

Data Sharing and Translation

CAD EXPORT FILE TYPES – Brief Listing
SCHEMATICS

.OPJ
.DXF
EDIF
.SCH
.DWG

DRAWINGS

.DWG
.DXF
.WMF

GERBER

.GBR

CAD IMPORT FILE TYPES – Brief Listing

SCHEMATICS

.OPJ
.DXF
EDIF
.SCH
PDIF

DRAWINGS

.DWG
.DXF
.WMF

GERBER

.GBR

EXPERIENCE WITH VERIBEST & MENTOR GRAPHICS DATA

PUI commits to use any software tool required by the customer

Test Equipment Capabilities

Projects Unlimited offers extensive in-house testing capabilities to our customers. Our years of experience provides for complete electrical and mechanical testing for high-reliability PCB’s, systems and sub-assemblies along with cables and associated harnesses. Our testing capabilities are supported by the latest technology and modern equipment to include:

Manufacturing Engineering

Manufacturing Engineering is an aggressive, proactive team of individuals. Through the use of wireless laptop computers, ME has developed a paperless environment for drawings, work instructions and specifications. They are the liaisons between manufacturing and the customer engineers. The team consists of Component, Process and Manufacturing Engineers with various support personnel and is responsible for the review and interpretation of all customer documentation and the development of a working set of manufacturing documents with which to build, inspect and test customer products. The team works side-by-side with manufacturing to refine working documents that ensure the most efficient, effective and repeatable methods of processing a product through our facility.

An extension of Manufacturing Engineering is the Pre-production & Development team (called PPD). This team of highly skilled, multi-tasking operators and engineers works directly with our customer in the development and/or refinement of products. We frequently work with an incomplete documentation package and can offer suggestions through the process that will enhance the “design for manufacturability”. This stage of manufacturing is often done for “Prototype or Product Qualification”. This team is also used for “small lot, quick turn” processing of customer products.

Program Management

Projects Unlimited has established an Integrated Product Team (IPT) to coordinate the activities involved in production of the customer’s product. The IPT concept promotes a close working environment leading to clear communication during all phases of the initial production program as well as through normal production operations. The Program Manager will facilitate communication among all members of the IPT, including customer representatives, as required. Close communication is always key to risk mitigation. Conference calls and video conferencing are just a few of the communication tools that are available.

This IPT concept has proven to be an excellent tool to maintain links as the program progresses. Projects Unlimited has applied this approach, with great success, with key customers, resulting in significant cost reduction while maintaining high quality standards and on-time delivery.

Materials Management

Projects Unlimited Inc. has a highly qualified, proactive supply chain management team. Our supply chain management team includes buyers and production control that resolve procurement issues quickly and effectively.

Projects Unlimited Inc. provides full, turnkey manufacturing services for most of its customers. We purchase material from a network of manufacturers, distributors and, in some cases, brokers, in order to support production needs. Maintaining close ties with representatives of these sources provides the company with early warning regarding parts availability issues and obsolescence, which we can then pass along to our customers.

Successful streamlining of the supply chain depends largely on the accuracy and frequency of forecast updates and Projects Unlimited will always work closely with its key customers and suppliers to facilitate sharing of production requirements.