Abstract: A method to make a flanged pin is described. The method includes feeding wire through a forming die whereby the wire is deformed to create a straight pin. The straight pin is then fed from the forming die to a heading die having a pre-formed cavity where a first portion of the straight pin is located in the forming die and a second portion of the straight pin is located in the heading die. A portion of the pin is secured in the forming and heading die, having a portion of the straight pin disposed in a gap defined by a space between the heading die and the forming die. As the die gap is closed, the portion of the straight pin is displaced into a pre-formed cavity thereby creating a flange.

Abstract: According to one embodiment of the present invention, a method for manufacturing thin film heaters includes an automated process for applying at least one layer of ink to a conductive substrate, and forming at least one electrically conductive electrode in electrical communication with the substrate by curing the ink. When an electrical current is applied to the thin film heater, current flowing through the substrate generates heat in the substrate. In alternate embodiments, a flexographic printing process is used to overlay two similar layers of ink on a carbon impregnated substrate and cure the ink to form at least one electrode conductor.

Abstract: A method and apparatus for manufacturing thin film heaters. According to one embodiment of the present invention, the method and apparatus includes an automated process for applying at least one conductor to a conductive substrate, where the conductor and the conductive substrate are in electrical communication. In alternate embodiments, a flexographic printing process is used to overlay two similar layers of ink on a carbon impregnated substrate and cure the ink to form at least one electrode conductor.