A gas generator usable in a vehicle occupant protection system. The gas
generator includes an initiator holder and an initiator secured within
the holder, the initiator including a housing enclosing an initiator
charge. A bore seal is molded into the initiator holder, and a casing is
attached to the bore seal along an exterior surface of the bore seal. A
gas generant material is positioned within the casing so as to enable
fluid communication between the gas generant and combustion products
formed by combustion of the initiator charge, thereby enabling ignition
of the gas generant. In one embodiment, an edge portion of the casing is
pre-formed so as to snap-fit over a shoulder formed along the bore seal.
In another embodiment, an edge portion of the casing is crimped onto
outer surfaces of the bore seal. In yet another embodiment, the casing is
welded to the bore seal.