Pyrotechnic initiator having output can with encapsulation material retention feature

1. A method of making a pyrotechnic initiator, comprising the steps of:

a) providing a header assembly having a top end and a bottom end, said bottom end including one or more electrical connectors;

b) providing an output can with an encapsulation material retention feature that extends inwardly on its bottom end;

c) attaching said output can to said header assembly;

d) encapsulating at least part of said bottom end of said header assembly and said encapsulation material retention feature with an encapsulation material in intimate encapsulated contact with said at least part of said bottom end of said header assembly and said encapsulation material retention feature; and,

e) attaching a circuit board to said electrical connectors, wherein said circuit board is laterally surrounded by said encapsulation material;

wherein said encapsulation material adjacent said encapsulation material retention feature does not substantially exceed the profile of said output can.

2. The method of claim 1 , wherein step b) is not completed until after step c).

3. The method of claim 2 , wherein step b) comprises swaging the bottom end of said output can.

4. The method of claim 1 , wherein step c) includes circumferentially laser welding said output can to said header assembly.

5. The method of claim 1 , wherein said header assembly includes a stamped eyelet.

6. The method of claim 1 , wherein said encapsulation material retention feature includes a swaged end.

7. The method of claim 1 , wherein said encapsulation material retention feature includes one or more stamped anchors.

8. The method of claim 1 , wherein said output can is attached to said header assembly with a through wall welding process.

9. The method of claim 1 , wherein said bottom end of said header assembly further includes a feature corresponding to said encapsulation material retention feature of said output can.

10. The method of claim 9 , wherein said encapsulation material retention feature includes a swaged end at said bottom end of said output can, and said corresponding feature of said header assembly comprises a circumferential bevel.

11. The method of claim 1 , wherein said encapsulation material retention feature at said bottom end of said output can does not extend outwardly beyond the profile of the rest of said output can.

12. The method of claim 3 , wherein said encapsulation material retention feature at said bottom end of said output can does not extend outwardly beyond the profile of the rest of said output can.

13. The method of claim 12 , wherein said swaging is performed with a one-step swaging tool.