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2017 CuTS Catalog

Copper Thermal Strap Standard Product Line

The Most Trusted and Affordable Thermal


Straps in the Industry

CuTS APPLICATIONS

Cryocoolers

Cryomodules

Optical Systems

IR Sensor Systems

Cold Laboratory
Instruments

TAI provides the Worlds only Copper Thermal Strap (CuTS) Standard Product
Line. Though our straps are made to the highest level of quality demanded by
NASA and the Aerospace Industry, they are affordable even on limited university and commercial electronics budgets. All CuTS products are:

Bolt Pattern & Braid Length-Customizable at No Charge (up to 60cm)

Particle Accelerators

Made Entirely of OFHC Copper (C10100) Rope and End Fittings

Semiconductors

Solder-Free and Never Brazed

Electronics Cooling

Designed & Assembled for Optimized Flexibility and Durability

Deployable Radiators

Heat Pipe Connections

Cold Heads

Thermally-Conductive
Vibration Isolation

LED Cooling

Medical Instruments

TAI COMPANY PROPRIETARY

To submit an inquiry or place an order, complete our CuTS Questionnaire,


and contact:
Tyler Link
Director of Business Development
Office: (303) 867.8145
Cell: (720) 917.4606
Email: tlink@TechApps.com
2016

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TAI
Ask About Our Reduced Prices and New Discounts!
Contact Us: 6 AM10 PM MST (12:00-04:00 GMT), 7 days/week

Copper Thermal Strap Catalog

Page 2

2017 ed.

C O P P E R T H E R M A L S T R A P ( C UT S ) S T A N D A R D P R O D U C T L I N E
In the 2017 edition of the Copper Thermal Strap (CuTS) Catalog, weve added even more
customization options, additional information on our strap
cleaning and testing services,
our manufacturing capabilities,
We have also rolled out our
new proprietary copper cabling,
OFHC
UltraFlex
(developed by TAI), which
offers increased flexibility over
our standard rope, while maintaining the same thermal performance and diameter.
New for 2016/17, we have reduced our already rock-bottom
prices, and we have also rolled
out substantial discounts for
University, National Laboratory, all New (and many) Returning Customers.

We have also been busy on the


R&D side of the business, and
released several new thermal
strap products which compliment our CuTS and GFTS
offering (visit our website to
learn more).

Please let us know how we can


improve our standard product
line, or any aspect of the ordering process. We are always
open to suggestions and happy
to help our valued customers!
-Tyler Link

At TAI, customer service and


efficiency are our top priorities.

Director of Business Development


Technology Applications, Inc.

OUTSOURCED & COUNTERFEIT STRAP SUPPLIER WARNING:


Unlike some Competitors, TAI never outsources our straps to
foreign companies, other thermal strap suppliers, or machine shops. All of our strap products are assembled by Our
Experts, At Our Facility, in Boulder, Colorado, to ensure your
straps are of the highest quality.
If for any reason, TAI cannot manufacture your straps, we
are happy to recommend a reputable supplier (one with
Flight Heritage, that does not make fraudulent claims about
their staff, facilities, or manufacturing capabilities).

Figure 1. Thermal conductivity of OFHC Cu (C101) compared with other common conductor materials. OFHC cu has an
average RRR content of 100200.

TAI COMPANY PROPRIETARY

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P5-501
The P5-501 is our original offthe-shelf CuTS option, and the
most flexible of the P5 series.
Braid length is customizable at
no additional charge (up to 60
cm). Bolt holes are optional.
Available with TAIs OFHC UltraFlex cu cabling at no additional charge.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.224 W/K
Projected Conductance (at 20K): 1.08 W/K
Approximate Weight: 163g

*The thermal conductance of a


CuTS is inversely proportional
to length (of the braided section), and it is not quite linear
(but fairly close). We do provide
projections at different temperatures and lengths.

P5-502
The P5-502 is our largest off-the
-shelf CuTS option available to
date. This unit is our most
thermally conductive and fairly
flexible, even with the additional 2nd layer (stiffness is only a
slight issue at braid lengths of
under 6-7 cm).

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.43 W/K
Projected Conductance (at 20K): 1.80 W/K
Approximate Weight: 260g

Braid length is customizable at


no additional charge (up to 60
cm). Bolt holes are optional.
Available with TAI OFHC UltraFlex cu cabling at no additional charge.

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P6-501
The P6-501 is 1 width
CuTS option, and the most
flexible of the P6 series.
Braid length is customizable
at no additional charge (up
to 60 cm). Bolt holes are optional. Available with TAIs
OFHC UltraFlex cu cabling
at no additional charge.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.11 W/K
Projected Conductance (at 20K): 0.54 W/K
Approximate Weight: 82g

*The thermal conductance of


a CuTS is inversely proportional to length (of the braided section), and it is not quite
linear (but fairly close). We
do provide projections at
different temperatures and
lengths.

P6-502
The P6-502 is our double row
version of the P6. This unit
is highly thermally conductive, extremely flexible (at
braid length >5-6 cm), more
compact , and offers a high
conductivity to weight ratio.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.21 W/K
Projected Conductance (at 20K): 0.93 W/K
Approximate Weight: 130g

Braid length is customizable


at no additional charge (up
to 60 cm). Bolt holes are optional. Available with TAIs
OFHC UltraFlex cu cabling
at no additional charge.

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P7-501
The P7-501 is our smallest option. It is the most flexible
standard strap; ideal for extremely confined spaces in your
system.
Braid length customizable at no
charge (up to 60 cm). Bolt holes
optional. Available with TAIs
OFHC UltraFlex cu cabling at
no additional charge.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.05 W/K
Projected Conductance (at 20K): 0.25 W/K
Approximate Weight: 39g

*The thermal conductance of a


CuTS is inversely proportional to
length (of the braided section),
and it is not quite linear (but
fairly close). We do provide
projections at different temperatures and lengths.

P7-502
The P7-502 is the double row
version of our smallest option. This unit offers higher
performance than the 501,
with a tiny weight increase,
yet maintains its extremely
small size. It is a highly flexible strap; ideal for confined
spaces in your application.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.10 W/K
Projected Conductance (at 20K): 0.44 W/K
Approximate Weight: 62g

Braid length customizable at


no charge (up to 60cm). Bolt
holes optional. Available with
TAIs OFHC UltraFlex cu
cabling at no additional
charge. Available with TAI
UltraFlex OFHC cu cabling
at no additional charge.

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P5-503 (L-SERIES)
The P5-503 (L-Series) provides
high thermal conductivity with the
convenience of the L-shaped end
fitting.
All straps are length customizable
at no additional charge (up to 60
cm). Bolt holes are optional. Available with TAIs OFHC UltraFlex cu
cabling at no additional charge.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.43 W/K
Projected Conductance (at 20K): 1.80 W/K
Approximate Weight: 304g

*The thermal conductance of a


CuTS is inversely proportional to
length (of the braided section), and
it is not quite linear (but fairly
close). We do provide projections
at different temperatures and
lengths.

P6-503 (L-SERIES)
The P6-503 offers the benefit of
the L-bracket end fitting, but with
a smaller total footprintideal
for applications with smaller interfaces and installation room to
work with.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.21 W/K
Projected Conductance (at 20K): 0.93 W/K
Approximate Weight: 152g

Braid length is customizable at no


additional charge (up to 60 cm).
Bolt holes are optional. Available
with TAIs OFHC UltraFlex cu
cabling at no additional charge.

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P7-503 (L-SERIES)
The P7-503 (L-series) is our smallest L-series strap, and provides
the smallest impact to your available envelope, while still providing
a high thermal conductance.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.097 W/K
Projected Conductance (at 20K): 0.44W/K
Approximate Weight: 73g

Braid length is customizable at no


additional charge (up to 60 cm).
Bolt holes are optional. Available
with TAIs OFHC UltraFlex cu
cabling at no additional charge.
*The thermal conductivity of a
CuTS is inversely proportional to
length (of the braided section),
and it is not quite linear (but fairly
close). We do provide projections
at different temperatures and
lengths.

P5-504 (U-SERIES)
The P5-504 (the U-Series), provides high thermal conductance,
with the convenience of a tight
c or u-shaped installation
configuration (ideal in tighter
areas with parallel interfaces,
requiring a high degree of flexibility). U-series straps are much
more flexible than our 502 and
503-Series units.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.41 W/K
Projected Conductance (at 20K): 1.75 W/K
Approximate Weight: 260 g

Braid Length is customizable (at


no charge) and bolt holes are
optional. Available with TAIs
OFHC UltraFlex cu cabling at no
additional charge.
**Please send pictures/sketches
of your envelope and interfaces
before ordering any 504-Series
straps.

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P6-504 (U-SERIES)
The P6-504 is our most popular Useries model, combining both high
thermal conductivity and flexibility
in a tight c/u-shaped installation
configuration.

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 300K): 0.21 W/K
Projected Conductance (at 20K): 0.90 W/K
Approximate Weight: 130g

Braid length is customizable at no


additional charge (up to 60 cm). Bolt
holes are optional. Available with
TAIs OFHC UltraFlex cu cabling at
no additional charge.

*The thermal conductance of a


CuTS is inversely proportional to
length (of the braided section), and
it is not quite linear (but fairly close).
We do provide projections at different temperatures and lengths.

P7-504 (U-SERIES)
The P7-504 is our smallest version
of the U-series straps. For its small
size, this unit is highly thermally
conductive, extremely flexible, and
more compact than the larger P6
and P5 series .

Performance Data & Mass


(at braid length = 10 cm):
Conductance (at 330K): 0.09 W/K
Projected Conductance (at 20K): 0.42 W/K
Approximate Weight: 62g

Braid length is customizable at no


additional charge (up to 60 cm). Bolt
holes are optional. Available with
TAIs OFHC UltraFlex cu cabling at
no additional charge.
**Please send pictures/sketches of
your envelope and interfaces before
ordering any 504-Series straps.

TAI COMPANY PROPRIETARY

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Page 9

T A I - C UT S C A T A L O G 2 0 1 7 E D .

P5-505 & 505R


Performance Data & Mass
(at braid length = 10 cm):
Conductance (at 300K): 0.42 W/K
Projected Conductance (at 20K): 1.80 W/K
Approximate Weight: 348g
*Available with TAIs OFHC UltraFlex cu
cabling at no additional charge.

P6-505 & 505R


Performance Data & Mass
(at braid length = 10 cm):
Conductance (at 300K): 0.21 W/K
Projected Conductance (at 20K): 0.92 W/K
Approximate Weight: 174g
*Available with TAIs OFHC UltraFlex cu
cabling at no additional charge.

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P7-505 & 505R


Performance Data & Mass
(at braid length = 10 cm):
Conductance (at 300K): 0.10 W/K
Projected Conductance (at 20K): 0.43 W/K
Approximate Weight: 84g
*Available with TAIs OFHC UltraFlex cu
cabling at no additional charge.

For CuTS Customization Options


See pages 1113
To submit an inquiry or place an order,
contact:

Tyler Link
Director of Business Development
Office: (303) 867.8145
Cell: (720) 917.4606
Email: tlink@TechApps.com
Available via Phone/Email:
6AM10PM MST (12:00 04:00 GMT),
7 days/week

TAI COMPANY PROPRIETARY

2016

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TA I S O F H C U LT R A F L E X C U C A B L I N G
TAI is proud to announce that all
of our custom and standard copper thermal straps now come
with two copper rope options, at
no additional cost.
In addition to our 0.1" diameter,
TAI Standard OFHC copper
braid (we've used for over a decade), TAI has developed a proprietary copper cabling, specifically
designed to provide increased
flexibility, while maintaining the
same diameter and thermal performance of our TAI Standard
OFHC cu braid. CuTS assemblies made with TAI's OFHC UltraFlex cabling are over 65% more
flexible than our standard straps
on the compression axis (X), and
average nearly 25% greater flexi-

bility on the Y and Z axes as well.


Customers that have previously purchased straps with the TAI Standard
OFHC cu braid will always have this
rope as an option (which is particularly helpful if you've already qualified our straps in your space/
airborne/terrestrial system), but for
applications where stiffness is a serious concern, OFHC UltraFlex is your
answer!

Above: OFHC UltraFlex straps average 65%


greater flexibility on the compression (x) axis, and
~25% greater on the Y and Z (lateral and vertical).
Left: OFHC UltraFlex has a tighter bend radius
than TAI Standard braid, and is ideal for applications with limited volume, and/or large range of
motion requirements.

C O M PA C T C UT S L O W P R O F I L E E N D F I T T I N G S F O R
MA SS REDUC TI ON & LIMITED INTER FACE AREA
All of our Standard CuTS models
(P5P7 series), are now available in
an optional Compact CuTS version.

model counterparts, and though the


overall footprint is smaller, the average conductance/performance loss
between compact and standard models is less than 2%.

In response to popular demand for


models optimized for reduced mass
and/or smaller footprints (for
smaller interfaces and cramped installation volumes), customers can
opt for the Compact version, for
just a small additional fee.
All compact model end fittings are
reduced in length from 1.0 to just
0.75, and end fitting thicknesses
are reduced from 0.25 down to
0.20 (for single row straps), and
from 0.35 to 0.30 (for double row
units).
End fittings of Compact straps are
30-40% lighter than their standard
TAI COMPANY PROPRIETARY

P6-501Compact Model
End Fittings on Compact Models are shortened and machined down for
a thinner/lower profile, resulting in significant mass and footprint
reductions.
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CUTS DESIGN GALLERY


TAI has designed, fabricated and
tested thousands of copper thermal straps for space, airborne,
and terrestrial applications. While
many of our straps are used in
space & satellite applications by
NASA, and aerospace organizations across the globe, they are
more commonly used in laboratory and commercial electronics
applications.

Cryomodule CuTS (Synchrotron)

These straps are not only a testament to our expertise, but our ability to accommodate a comprehensive array of customer demands.
The following are just a few examples of the thousands of straps we
have designed and fabricated for:
Cryomodule, Particle Accelerator,
Cryocooler, Satellite , Planetary
Rover, Commercial Electronics, Optics, and Semiconductor applications:

Cold Head Custom FM CuTS

Dual and Tri-Armed Custom CuTS

NASA FM CuTS - Mitered Fittings

Cold Head Custom CuTS

Pipe Clamp / Pipe Interface Fittings

Camera System CuTS

NASA FM Electronics Box CuTS

P6-503 CuTS Cold Head

NASA JPL FM CuTS - Offset Fittings

P6-503 CuTS - Counterbored Holes

NASA Mars Rover Prototype CuTS

Single Rope CuTS - Counterbored

TAI COMPANY PROPRIETARY

Telescope Custom CuTS:

Nested Cryocooler Custom CuTS:

Optional 0.2 Diameter Cu Cabling for

Optional Aluminized Mylar Overwrap.

increased flexibility, with Counter-

Assembly contains 4 nested, double

bored Bolt Holes and Pins

row thermal straps

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CUSTOM CuTS & OPTIONS


If a standard model will not work for
your system, TAI can produce nearly
any custom configuration to meet
your needs. Weve specialized in custom CuTS design and fabrication for
over 12 years, and our experts are
here to help.
We offer optional serialization, aluminized mylar sleeves/overwraps, different rope diameters, and helicoil inserts, and our experts can design &
fabricate end fittings with complex

and extremely-challenging geometry.


New for 2016, customers also have the
option to use 5Nines (99.999% pure)
OFHC cu rope and fittings, for a small
additional fee.
All custom straps require some level of
NRE and design time, and this will increase the price of a program by a
small amount, as well as increase lead
time to 6-10 weeks. Large orders of
straps (20-100+ units), may take an
additional 2-6+ weeks, depending on

Nested ConfigurationsHigh Density Packaging


for High Thermal Conductance Applications

quantity.
Submitting an Inquiry or RFQ:
Send TAI a CuTS questionnaire and
any available drawings or .stp files of
your envelope & interfaces, and we
can get you an assessment within 2-3
business days.
Please note that attempting to design
straps yourself will not reduce NRE
and often causes significant problems.
All custom straps incur an affordable,
one-time design fee, but all initial assessment and notional design work is
free of charge.

Aluminized Mylar Overwrap for Radiation Heat Transfer Control

Multi-Planar Interface

Helicoil Inserts

Custom Rope Diameters and Types

Serialization

For applications with limited volume and/or high flexibility


requirements, TAI has qualified OFHC cu braid and cabling
with diameters ranging from 0.07 - 0.20. We are happy to
use any size or type of rope/cabling you require, though a
prototype program is required for unqualified material.
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Page 14

CUTS TESTING & CLEANING S ERVICES


Shock & Vibe Testing
Thermal testing is included in GFTS programs, and one free thermal test is included in any CuTS custom or standard
order (additional strap tests are provided at an affordable rate).
Thermal Cycling

TAI provides a comprehensive range of


strap testing services for clients, both
in-house, and with our test facility
partners in Boulder, CO, and California.
While some testing is complimentary/
included in certain programs, other
testing can be added to your programs
at reasonable costs, if desired.
Our sister organization, TAI,
Inc. (www.tai-inc.us) also provides
some thermal strap testing services for
Technology Applications, Inc., in addition to their thermal strap R&D and
Government Contracting work.

TAI provides in-house thermal cycling of


all of our thermal strap products. We
have the capability to perform cycling
down to 77K, and up to (in excess) of
475K.
Contact us to discuss your specific requirements. More information on our
Thermal Cycling Test Services will be
coming shorty. To discuss your specific
testing needs, contact TAI today.

TAI can provide shock and vibe testing


for your program for an affordable rate.
Please plan for an additional 1-3 weeks
depending on the amount and complexity of testing. Space qualification / shock
and vibe heritage data is available to aerospace clients upon request.
Thermal Strap Cleaning

Stiffness Testing

Thermal Conductance Testing

In-house stiffness testing is available for


all of our CuTS and GFTS products for a
small additional fee.

Thermal conductance testing


is provided on site at TAI. TAI's highly
trained thermal strap technicians perform thermal testing on all of our strap
products in our custom built vacuum
chambers. Our main chamber (pictured
on the right), has a 36" diameter, and
an interior height of 24". While we
currently only test at room temperature (~295K), TAI is designing modifications to our main chamber, in order to
test thermal conductance down at 77K,
and we are developing the capabilities
to test down to liquid helium temperatures.
TAI COMPANY PROPRIETARY

With all stiffness tests, unique tooling is


designed and used to test the straps
stiffness in any desired position for all
axes. Any positive or negative displacement relative to the straps neutral position can be measured, and the force
and displacement is measured using
NIST traceable calibrated transducers.
To learn more about our stiffness
testing services, and for sample stiffness
test data on previous copper and graphite thermal straps, please contact us
today.

2016

After fabrication, all straps are tested,


ultrasonically cleaned, and bagged prior
to shipping. TAI offers optional nitrogen
purged bags for shipping, but we also
recommend that any strap used in a
UHV, sensitive optical, or space/satellite
application, undergo any additional
cleaning spec/procedure your organization requires for copper hardware (some
aerospace customers will perform an
additional round of ultrasonic cleaning in
a bath of Citranox, or various copper
cleaners, and then perform a vacuum
bakeout prior to installation).
TAI contracts with a partnering test and
cleaning facility to perform cleaning in
cases where straps must be cleaned to a
specific cleanliness specification
(common in satellite optical applications).
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OFHC Cu FOIL THERMAL STRAPS (C UFTS)


Generally, thermal straps made of
braided copper ropes offer the best
overall flexibility-to-thermalconductivity ratio, and the lowest
cost of any metal strap configuration.
However, there are instances where
flexibility is not needed in all axes,
and tight packaging constraints
(limited volume) coupled with high
thermal conductance requirements,
may make an OFHC copper foil thermal strap (CuFTS) a superior solution. In such cases, CuFTS may provide a lower mass and lower volume
alternative to the more conventional
copper-braid straps.

TAI can design and fabricate a broad


array of OFHC copper foil straps, and we
will be releasing our first Foil Strap Catalog in 2017.
CuFTS can be made in any thickness,
width and length, and can be designed
and fabricated into complex shapes for
installation in confined routes in your
system.
They are ideal for cryogenic and vacuum
environments, and OFHC copper foils
with very high RRR values/purity can be
ordered upon request, for an additional
increase in price.

TAI offers the same testing and add-on


options as our CuTS product line.
Please be aware that stiffness testing
may be critical to your program, as nearly
all foil straps are far less flexible than
their rope counterparts.
To discuss your CuFTS inquiry or to
place an order, contact our Director of
Business Development, Tyler Link.

As with our popular CuTS products,


TAI will manufacture both custom and

Low Profile CuFTSIdeal for Extremely-Limited Volume to High Thermal Conductance Ratio Applications

TAI COMPANY PROPRIETARY

standard CuFTS (standard models will


be released later this year). Please note
that the cost of any CuFTS will be higher than copper rope straps due to higher
material and fabrication costs.

Traditional CuFTSWidth & Thickness Customizable.


Also Offered in S, U, and Straight Configurations.

2016

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To submit an inquiry or place an order, contact:


Tyler Link
Director of Business Development
Office: (303) 867.8145
Cell: (720) 917.4606
Email: tlink@TechApps.com
Available via Phone/Email:
6AM10PM MST (12:00 04:00 GMT), 7 days/week

TAI