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A system for a piston actuator comprising a configuration with lead styphnate charge material and Nichrome® bridgewire, wherein the device configuration provides very high reliability, including piston actuator applications; resistance of the bridgewire is carefully controlled to optimize power tran

A system for a piston actuator comprising a configuration with lead styphnate charge material and Nichrome® bridgewire, wherein the device configuration provides very high reliability, including piston actuator applications; resistance of the bridgewire is carefully controlled to optimize power transfer from the firing circuit to the bridgewire and charge material.

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1. A method for manufacturing a miniature piston actuator, said method comprising the steps of: providing a header electrode assembly comprising a header and an electrode, said header having a first end and a second end, said first end comprising a planar surface, said planar surface having a should

1. A method for manufacturing a miniature piston actuator, said method comprising the steps of: providing a header electrode assembly comprising a header and an electrode, said header having a first end and a second end, said first end comprising a planar surface, said planar surface having a shoulder cut-out around perimeter of said first end, said header defining an aperture through a center portion of said header extending from said first end to said second end, said header size corresponding to an M100 designation, an outer diameter of said header being approximately 0.100 inch, and there not being more than one electrode having a first end and a second end, said first end of said electrode extending within said aperture of said header, said first end of said electrode being flush with said planar surface of said first end of said header, and there is a glass insulator within said aperture of said header, said glass insulator providing a glass fill seal between said electrode and said aperture of said header, and said glass insulator being flush with said planar surface of said first end of said header;welding a bridgewire to the electrode of said header electrode assembly, said bridgewire forming a circuit between said header and said electrode, said header and said bridgewire comprising a header/bridgewire assembly, wherein resistance of said bridgewire is controlled to ensure that a minimum all-fire energy of said device is available from a firing circuit;installing a ferrule, said ferrule comprising a ring having a first end and a second end, and dimensions of said second end of said ferrule corresponding to said shoulder cut of said header, said second end of said ferrule being located in said shoulder cut of said first end of said header;applying charge material within said ferrule, said charge material being filled to be plane with said first end of said ferrule, said charge material adapted to be activated by a current through said bridgewire, and reliability of said piston actuator activation exceeding approximately 99.5 percent of said activated charge material becoming an expanding gas;installing a piston, said piston proximate said charge material, said piston being moved to provide mechanical output by said charge material expanding gas, said piston, said header, said ferrule, and said bridgewire comprising a piston header ferrule/bridgewire assembly; and installing a discrete housing around said piston header ferrule/bridgewire assembly, said housing having a first end and a second end, said first end of said housing defining an opening having a diameter through which said second end of said single electrode extends, and said diameter of said opening of said first end of said housing being less than said diameter of said header, said housing having a cylindrical inner diameter larger than said diameter of said header, and said header, ferrule, and the piston sliding Iv fitting within said housing, and said second end of said housing open to receive said piston header ferrule/bridgewire assembly, such that said piston provides said mechanical output to initiate said electronic thermal battery by striking, said electronic thermal battery. 2. The method of claim 1 wherein said piston actuator comprises: charge material consisting essentially of lead styphnate (LS), whereby flow overcomes effects of voids and fissures, fills gap between header and glass fill seal, and flows around circumference of said bridgewire increasing surface area; andsaid bridgewire comprises a nickel chromium alloy. 3. The method of claim 1 wherein function time of said piston actuator comprises: a minimum of about 38 microseconds;an average of about 58 microseconds; anda maximum of about 134 microseconds. 4. The method of claim 1 further comprising the steps of gold plating said header. 5. The method of claim 2 further comprising the step of milling said LS to about 30 hr mil, whereby said particle size is reduced, improving said flow. 6. The method of claim 1 wherein said miniature piston actuator is an electro-explosive device (EED) comprising part of an electronic thermal battery initiator (ETBI) to provide a mechanical output to initiate a thermal battery.