An electronics designer needed to place a Dallas Semiconductor Integrated Circuit on a circuit board where space was at a premium. An available snap-in socket was too large.
B. Dash Fabrication designed and built a spot welder that bonded 0.005" thick nickel/steel strips to the Stainless Steel IC package. The strips could then be soldered directly to the board. We also developed hardware to test the ICs before and after welding.
The design was accepted for production, and B. Dash welded the strips to the ICs in batches of 50 to 200. With the procedures we developed, we achieved IC failure rates in process of well under 1%, and delivered 100% good product.