BREAKING THERMAL AND MATERIAL BARRIERS
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OUR VISION
To be your preferred
partner for innovative,
high-performance
thermal management
and material solutions.
MISSION
Because a project’s success depends on working with qualified team members, Thermacore puts the capabilities of an expert
partner on your side. We lead our industry in the invention, development and manufacturing of the best performing and most
reliable thermal management and material solutions.
You’ll find we provide the expertise you need to succeed through our commitment to collaborative, “outcome-driven” customer
partnerships, breadth of thermal and material technologies, technology development, unique manufacturing capabilities, product
reliability and global manufacturing, engineering and support services.
CULTURE
Thermacore is a technology (> 100 patents) and manufacturing
company with over 40 years of experience and heritage in the
custom design, development and manufacturing of highly
engineered, high-performance thermal management and
material solutions. Our unique company culture, strategy, goals
and values provide an ideal environment that ensures our
customers’ success.
As a technology and manufacturing company, we apply our
Intellectual Property (IP), trade secrets and know-how to solve
complex thermal and material problems for our customers and
help to “enable” our customers’ products. We are more than just
a manufacturer of products; we are solution provider. We provide
complete or total life cycle thermal solutions, taking a customer’s
basic thermal and material problem and delivering a solution from
concept through design, development and manufacturing.
Our strategy is focused on technology, innovation, unique
manufacturing abilities and growing our business by extending
“Outcome-driven Customer Partnership”—Our experience and
our core capabilities to create competitive advantages and
research show that with our Know-How, Customer Collaboration
CUSTOM
value for our global customers.
Our goals are focused on
and focusVALIDATION
on a Return on Investment
(ROI), we can help our
CONCEPT
PROTOTYPE
MANUFACTURING
ENGINEERING
TESTING
& PRODUCTION
DESIGNproductDEVELOPMENT
growing our customers’DEVELOPMENT
success though innovation,
customers&win
in their marketplace
better than anyone else. That is
and service breadth, maintaining customer focus through
our “sweet spot.” The reason we are in business is to not only help
“outcome-driven customer partnerships,” world-class talentNEXT GENERATION
our customers meet their project’s stated goals, but to allow our
and improving productivity.
customers to differentiate their products and grow their business.
Our Outcome-Driven Project Cycle
CONCEPT
DEVELOPMENT
CUSTOM
ENGINEERING
DESIGN
PROTOTYPE
DEVELOPMENT
VALIDATION
& TESTING
NEXT GENERATION TECHNOLOGICAL ADVANCEMENT
MANUFACTURING
& PRODUCTION
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CORE COMPETENCIES
Thermacore has a proven track record of developing advanced thermal and material solutions
for a variety of applications and markets.
Our Core Competencies include:
• Concept through Mass Production for Total Life Cycle Support
• Pre-production and Mass Production
• Industry’s widest array of proven passive and active thermal
• Metallurgical Services, including custom metal alloy processing,
and materials technologies, products and custom solutions
testing and characterization
• Next Generation Technology Development and Commercialization
• Quality Commitment Using Lean Six Sigma
• Collaborative Partnership Business Model
• Reliability proven with 40+ years of fielded product in
• Multi-disciplinary Engineering and Manufacturing Teams
Mission Critical Systems
• Thermal/Mechanical Analysis and Design
• Outcome-driven Project Management
• Prototype Development and Qualification Testing
• Global, Vertical Integrated Engineering and Manufacturing Services
ADVANCING TECHNOLOGY
In 1970, Thermacore was founded to develop and commercialize
a passive, two-phase heat transfer device called a “heat pipe”— a
highly thermally conductive device that moves heat with a small
temperature difference. Over the past 40 years, Thermacore
has not only commercialized the heat pipe but established
the sintered, copper-water heat pipe as the world standard for
electronics cooling. Sintered powder metal (SPM) wicking is the
only technology demonstrated to offer freeze thaw tolerance and
to operate against gravity. As a result, SPM heat pipes are now
the most widely manufactured in the world. Today, we are the
industry leader in the design, development and manufacturing
of heatpipe-based thermal solutions, providing “best-in-class”
performance and the highest levels of quality and reliability.
Beyond heat pipe technology, we have expanded our thermal
and material technologies to be the broadest in the industry.
Our unique leading-edge solutions and capabilities include the
k-Core® Annealed Pyrolytic Graphite (APG) composite system,
heat pipe and vapor chamber assemblies, loop heat pipes, cold
plates (k-Core®, embedded heat pipe and liquid cooled-based),
ruggedized pumped liquid cooling systems, Intelligent Thermal
Management Systems (iTMS), cabinet/enclosure cooling heat
exchangers, CTE matched thermal technologies and a complete
range of metallurgical services, including specialty materials
production and the crafting of alloys that no one else in the
world can make. Plus a full menu of fabrication services: metal
joining, aluminum vacuum brazing, testing, characterization
and more.
Next-generation Technologies—When it’s time for your product
to move into the next-generation and evolve into a smaller, lighter,
more durable or more powerful, higher-performance technology,
our experts will partner with your engineering team to transform
your product again. We enable your next generation of products
through our unique combination of thermal management and
materials expertise, manufacturing equipment and aggressive
investment in new thermal and material technologies. The result is
the creation of groundbreaking products.
RESEARCH & DEVELOPMENT
In developing advanced thermal and material technologies for
the next generation military/aerospace and commercial systems,
Thermacore has been awarded contracts by Defense Advanced
Research Projects Agency (DARPA), NASA, Department of Defense
(DoD), European government agencies, as well as prime U.S.
contractors, such as Lockheed Martin and Raytheon.
From 1983 to 2000, Thermacore received more than $50 million
in contracts under the Small Business Innovative Research (SBIR)
program. More recently, Thermacore was awarded a $10 million
development contract with DARPA for the development of
Micro-Technologies for Air Cooled Exchangers (MACE) to improve
air side cooling in military systems. The European Union (EU) has
also funded Thermacore with $6 million for the development of
enhanced “nano” fluids and systems for actively pumped liquid
cooling of electronic systems. These technology efforts exemplify
the direction in which Thermacore is moving to solidify its
leadership in the advanced thermal management arena.
Thermacore’s technology leadership position is a by-product
of its most important asset: its people. Thermacore employs a
multidisciplinary team of thermal and materials engineers who
are the leaders in their fields. With more than 50 engineers
worldwide, who are dedicated to thermal management and
advanced materials, Thermacore has generated over 200 patents
and authored over 1,000 technical papers.
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GLOBAL MANUFACTURING CAPABILITIES & SERVICES
Every phase of a product’s life cycle is covered by Thermacore’s comprehensives services: from prototype creation through
volume production, utilizing flexible, vertically integrated factories and a highly experienced staff. Our breadth of thermal
and material technologies and product solutions are supported by manufacturing capabilities unmatched in the industry.
Thermacore’s manufacturing capabilities include:
Fabrication
Quality and Validation Testing
Product manufacturing services include product build-to-print, fabrication, assembly and system integration. Other related
services include supply chain management, Total Quality Assurance (identification of KPIs and ongoing measurement),
product validation and performance testing.
• Precision CNC Machining Centers
• Metal Joining (Soldering, Brazing, Welding, Adhesive Bonding,
Diffusion Bonding and Fusing)
• Metal Forming (Swaging, Bending, Flattening and High-strain
Rate Forging and Extruding)
• Aluminum Vacuum Braze Furnaces
• Aluminum Controlled Atmosphere Brazing (CAB) Belt Furnaces
• Heat Treating and Aging
• Mechanical Conformance—Coordinate Measuring
Machines (CMMs), Optical Comparators
• Thermal Testing (Power, Heat Load, Heat Flux, Temperature
and 100% Final Assembly Thermal Testing)
• Hydrodynamic Testing (Pressure Drop and Flow Rate)
• Thermal Cycling (Freeze/Thaw) and Thermal Shock
• Life and Reliability Testing
• Helium Leak Testing, including vacuum leak and
pressurized article
• Custom Lab View Data Acquisition Stations
• Hardness Testing
• High-temperature Vacuum Tensile Testing
• Hydrostatic Ultra-low Vacuum Creep Testing and Aging
• Fatigue and Compression Testing
• Impact Testing
• Corrosion Testing
• Drop Testing
• O-ring material testing for commercial nuclear plant
applications, with precise temperatures and water pressure
control to assure the product meets all specifications
Thermacore’s AS 9100 and ISO-certified manufacturing centers provide over 200,000 square feet of manufacturing space.
Thermacore is headquartered in Lancaster, Pennsylvania USA. Other U.S. locations include: Langhorne, Pennsylvania; Rostreaver,
Pennsylvania (near Pittsburgh); and Ronkonkoma Long Island, New York. Our European base of operation is located in United
Kingdom (Ashington, Northumberland), which includes manufacturing facilities as well as a dedicated engineering and sales
team. Located in Shenzhen, Thermacore China and key strategic partners across Asia provide our customers with access to
Thermacore’s advanced technology, thermal and material innovations, and localized Low Cost Country (LCC) manufacturing.
Specialty Processes
• Annealed Pyrolytic Graphite (APG) production with CVD highconductivity graphite growth furnaces for producing our k-Core®
• Heat Pipe/Vapor Chamber/Loop Heat Processes (wick sintering,
fluid processing, mechanical forming and thermal testing)
• Cryomilling of aluminum or magnesium alloy powders in liquid
nitrogen or argon
• Custom Metal Alloy Processing, including refractory alloy
development through button melting (DC), vacuum arc
remelting (AC) and other melting and processing capabilities
• Cold Isostatic Pressing (CIP) and Hot Isostatic Pressing (HIP)
• Autoclave and Out-of-autoclave Processing
Assembly and Integration
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Internal Tool and Die Design and Fabrication
Custom Assembly Fixtures, Jigs and Tools Design and Fabrication
Custom Equipment Fabrication, including testing and validation
Mechanical Assembly and Integration, including Thermal
Module and Systems
Services
• Materials Analysis Services, including metallography,
scanning electron microscopy and residual gas analyzing
• Composite Material and Process Development
• Consultation on Failure Analysis and Mechanical Design
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PRODUCTS, TECHNOLOGIES & CAPABILITIES
Whether your application is military/aerospace, government, computer, communication, energy conversion, medical, transportation,
test equipment or automotive, Thermacore provides leading custom and standard thermal management and material solutions
for a global market. We provide complete or total life cycle thermal solutions, taking a customer’s basic thermal or material problem
from concept through design, development and manufacturing of the solution. In a typical customer engagement, we partner with
our customers to develop custom thermal management and material solutions for component level, subsystem level and system level
problems across a wide operating temperature range from “cryogenic” (minus 265°C to 0°C) to “high temperature” (> 2000°C).
MANAGEMENT & PERSONNEL
Thermacore’s product and service capabilities include:
When working with Thermacore, you can draw on the expertise of engineering and management teams with established track
records in technology development, product commercialization and volume manufacturing. We have pioneered and commercialized
numerous thermal and material technologies, including k-Core® (encapsulated annealed pyrolytic graphite), heat pipes, vapor
chambers, loop heat pipes, liquid cooling, thermal straps and high-temperature and composite materials. We maintain over 100 patents
awarded to personnel who are inventors or co-inventors of more than 200 U.S. and international patents and the authors of more than
1000 technical and scientific publications.
Thermacore employs more than 180 employees and includes an experienced staff of 50+ engineers (Bachelor’s, Master’s, Ph.D.’s —1000+
man-years of experience) in diverse fields such as mechanical, electrical, chemical, aerospace, materials, manufacturing and physics.
TOTAL LIFE CYCLE SOLUTIONS
From Concept to Production
Qualification/Validation Testing
• Design, Development and Manufacturing of
Advanced Thermal Management and Material Solutions
• Industry and Proprietary Design Tools
• Technology Development of Next-generation Solutions
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Thermal Performance
Thermal Cycling and Shock
Hydrodynamic Testing (Air and Liquid Fluid Flow/Pressure Drop)
Pressure Cycle Testing
Leak/Proof/Burst Testing and Hydrostatic to 10,000 psig
Mechanical Shock and Vibration
Environmental
Engineering Services
Graphite-based solutions
(Thermal, Mechanical
and Materials)
• Advanced Solid Conduction:
k-Core® Annealed Pyrolytic
Graphite (APG) System
• Thermal Straps, graphite and
all metal (aluminum and copper)
• Contract R&D
• Concept Creation
and Generation
• Analysis, Design and
Development
- SolidWorks®
- FloTHERM®, CD-adapco
STAR-CCM+®, COSMOS/M
and ANSYS Icepak
- Proprietary Software for
k-Core®, Heat Pipe, CCHP,
Vapor Chamber and Loop
Heat Pipe Analysis
• Heat Transfer:
- Conduction, Convection
and Radiation
- Single and Two-phase
Fluid Flow
- Heat Pipes, Vapor Chambers
and Loop Heat Pipes
• Fluid Mechanics: Fluid Flow
(Laminar and Turbulent)
• Structural and Mechanical
Analysis:
- Static, Dynamic (Time
History, Random, Shock)
- Nonlinear (Material and
Geometric)
• Program and Project
Management
Heat Pipe and Other
Passive Two-phasebased Solutions
• Heat Pipes and Heat Pipe
Assemblies
- Constant Conductance
Heat Pipes (CCHPs)
- Variable Conductance
Heat Pipes (VCHPs)
- Cryogenic Heat Pipes
(-265°C to 0°C)
- High-temperature Heat Pipes
(> 300°C to 2000°C)
- Isothermal Furnace
Liners (IFLs) and Black
Body Cavities
• Vapor Chambers and Vapor
Chamber Assemblies (Flat or
Planar Heat Pipes)
• Loop Heat Pipes
• Phase-Change Material (PCM)
Solution
Cold Plates and Heat
Spreader Plates
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k-Core® APG-based Cold Plates
Embedded Heat Pipe Cold Plates
Vapor Chamber Cold Plates
Liquid Cooled Cold Plates
Aluminum Vacuum Brazed
Cold Plates
• Coefficient of Thermal Expansion
(CTE) matched cold plates
Active Pumped Systems,
Complex Thermal
Control Systems and
Thermal Storage
• Pumped Liquid Cooling Systems
(Commercial and Ruggedized)
• Pumped Two-phase Systems
• Intelligent Thermal Control
Systems (iTMS®)
• Ruggedized Thermal Control
Systems
• Thermal Storage Systems
Heat Exchangers for
Cabinet Cooling, Energy
(HVAC) and Waste Heat
Recovery
• Air-to-Air, Liquid-to-Air and
Liquid-to-Liquid Heat Exchangers
• Heat Pipe and Impingement-based
• Aluminum Vacuum Brazed
Heat Exchangers
• Standard and Custom
Brazing and Brazement
Assemblies
• Aluminum Vacuum Brazements
(Cold Plates, Assemblies and Chassis)
• Aluminum Controlled
Atmosphere Brazing (CAB)
• Heat Treating and Aging
• Copper Vacuum and
Atmosphere Brazing
Metallurgical Services
• Materials Testing and
Characterization
• Metal Joining—Sintering, Soldering,
Torch Brazing and Welding
Testing Services
• Thermal Testing (Power, Heat
Load, Heat Flux and Temperature)
• Hydrodynamic Testing (Pressure
Drop and Flow Rate)
• Thermal Cycling (Freeze/Thaw)
and Thermal Shock
• Helium Leak Testing,
including vacuum leak and
pressurized article
• Leak/Proof/Burst Testing and
Hydrostatic to 10,000 psig
• High-g Spin Table Testing
(up to 15g’s)
• Life and Reliability Testing
• Hardness Testing
• High-temperature Vacuum Tensile
• Hydrostatic Ultra-low Vacuum
Creep Testing and Aging
• Fatigue and Compression Testing
• Impact Testing
• Corrosion Testing
Manufacturing Services
• Machining—CNC Precision
Machining (Lathe and Mill)
• Product Build-to-print,
Fabrication, Assembly and
System Integration
• Supply Chain Management
• Total Quality Assurance
(identification of KPIs and
ongoing measurement)
• Product Validation and
Performance Testing
• Contract Manufacturing Services
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COMPLIANCE WITH QUALITY, RELIABILITY,
ENVIRONMENTAL & REGULATORY STANDARDS
• Thermacore facilities are certified to AS 9100 Rev C.,
ISO 9001:2008 and ISO 14001:2004 quality standards
• RoHS and RoHS 2 Compliant as required
• Department of Defense Trade Controls
(DDTC)/ITAR Registered (Active)
• Thermacore’s Standard HXi Cabinet Cooling
Heat Exchangers are Underwriter Laboratory (UL)
tested and certified
• Largest Collection and Longest Running Heat Pipe, Loop Heat Pipe,
and Vapor Chamber Life Test Collection
Qualified to Industry Standards
Thermacore’s aluminum vacuum brazing/heat treating
and welding services are conducted to meet the industry
standards given in the table at the right.
Industry Standard
Description
AWS C3.3
Recommended Practices for the Design,
Manufacturer and Examination of Critical
Brazed Components
AWS C3.4
Specification for Torch Brazing
AWS C3.6
Specification for Furnace Brazing
AWS C3.7:2005
Specification for Aluminum Brazing
AWS B2.2:2010
Specification for Procedure and
Performance Qualification
AMS 2678:2006
Furnace Brazing of Part in a
Vacuum Atmosphere
AMS 2750D:2005
Pyrometry
AMS 2770H:2006
Heat Treatment of Wrought
Aluminum Parts
MIL-H-6088G,
Notice 1:1997
Heat Treatment of Aluminum Alloys
MIL-B-7883C,
Notice 1:1996
Brazing of Steels, Copper, Copper Alloys,
Nickel Alloys, Aluminum and
Aluminum Alloys
AWS D17.1:2001
Specification for Fusion Welding for
Aerospace Applications
AWS B2.1
Base Metal Grouping for Welding
Procedure and Performance Qualification
AWS QC1
Certified Welding Inspectors
MIL-STD-2219A
Fusion Welding for Aerospace Applications
MARKETS/VERTICALS
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Aerospace
Communication
Computer/Data Center
Electronics
Government
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Industrial
Material Science
Medical
Military/Defense
PetroChemical
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Power Electronics
Processing
Renewable Energy/Energy
Test Equipment
Transporation/Automotive
EXAMPLE APPLICATIONS
AEROSPACE/MILITARY
COMMERCIAL
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Computer and Data Centers
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Aircraft Wing and Engine Cowl De-icing
Antenna Cooling
Avionics Cooling
Communications Electronics Cooling
Composite Materials
Custom Specialty Alloy Fabrication
Electronic Enclosures
Electronic Warfare/Jamming Equipment
Cooling
Embedded Computing Cooling
Guidance System Electronics Cooling
Heat Exchangers for Cabinet/Enclosures
Hypersonic Leading Edges Thermal Protection
and Cooling
Image Processing
Lasers
Power Electronics Cooling
Missile Body/Nozzle and Electronics Cooling
Radar Electronics Cooling
Satellite Payload Thermal Control and
Spacecraft Radiators
Vetronics Cooling
• Computer Processor Cooling
• Multi-Chip Modules and PCB Cooling
• Data Centers (Racks, Blade Servers)
Communications
• RF Amplifiers
• Base Station Cooling
• Cabinet/Enclosure Cooling
Power Electronics
• IGBT’s, SGCT’s, Thyristers, SCR’s, TRIACs
• Rail Transit Propulsion, Industrial Drives,
Escalators, UPS’s, and Welding Equipment
Medical Device and Equipment
• Surgical Tools
• Imaging and Analyzer Equipment
• Test Equipment
Other
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Automotive Electronics and Batteries
Commercial Aircraft
HVAC and Waste Heat Recovery
LED Lighting
Material Processing
Solar Concentrators
GOVERNMENT EXPERIENCE
• Air Force Research Laboratories, US Air Force
Materials Command, US Air Force and
USAF\AFMC Air Force Research Laboratory
• Army Research Laboratory
• Defense Advanced Research Projects Agency
(DARPA)
• Advanced Research Projects Agency-Energy
(ARPA-E)
• Missile Defense Agency (MDA)
• NASA
• Naval Air Warfare Center, Naval Sea Systems
Command, Naval Surface Warfare Center,
Navy Sea Logistics Center and Office of Naval
Research
• European Space Agency
• European Union (EU) Seventh Framework
and Horizon 2020 programs
• United Kingdom Technology Strategy Board
PIONEERING THERMAL AND MATERIAL MANAGEMENT
Before 1970, the heat pipe was an experimental technology. Then, a
small group of visionary engineers from RCA formed Thermacore—
transforming and growing this thermal management technology
into a viable solution for countless applications all over the world.
Today, Thermacore is recognized as the global leader in heat pipe
technology, having been the catalyst and leader in moving the
sintered powder metal (SPM) wick heat pipe from a laboratory of
curiosity to the global standard.
But thermal engineers don’t just turn to Thermacore for heat pipes;
they also turn to Thermacore for the broadest offering of unique
thermal and materials technologies in the world, along with world
class global manufacturing capabilities and services. Using creative
and collaborative approaches, Thermacore knows how to develop
and manufacture the right solutions for each thermal and materials
challenge. By applying groundbreaking approaches and unrivaled
engineering expertise we deliver highly engineered thermal
management and material solutions of unmatched performance.
Thermacore is ready to break through your thermal and material
barriers. Count on us to handle your complete and total product
life cycle, from concept through design, development and
manufacturing of high-performance solutions.
SINCE 1970… BREAKING THERMAL AND MATERIAL BARRIERS
North America
Thermacore, Inc.
k Technology Division
Corporate Headquarters
780 Eden Rd.
Lancaster, PA 17601, USA
Phone: 717-569-6551
Fax: 717-569-8424
2000 Cabot Boulevard West
Suite 150
Langhorne, PA 19047, USA
Phone: 215-375-3035
Fax: 215-375-3040
Materials Technology
Division
440 Jonathan Willey Rd.
Belle Vernon, PA 15012, USA
Phone: 724-379-1490
Fax: 724-379-1495
[email protected]
Europe
Asia
Thermacore Europe, Ltd.
Thermacore China
12 Wansbeck Business Park
Ashington
Northumberland, UK NE63 8QW
Phone: +44 (0) 1670 859 500
Fax: +44 (0) 1670 859 539
Room 1801 North Building
Tai Ran Cang Song Mansion
No. 6 Tai Ran Road, Fu Tian
District Shenzhen
www.thermacore.com
AS 9100 • ISO 9001 Certified • DDTC/ITAR Registered
© 2015 Thermacore, Inc.
LOCATIONS