BREAKING THERMAL AND MATERIAL BARRIERS

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To be your preferred

partner for innovative,

high-performance

thermal management

and material solutions.

OUR VISION

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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.

Our strategy is focused on technology, innovation, unique manufacturing abilities and growing our business by extending our core capabilities to create competitive advantages and value for our global customers. Our goals are focused on growing our customers’ success though innovation, product and service breadth, maintaining customer focus through “outcome-driven customer partnerships,” world-class talent and improving productivity.

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.

“Outcome-driven Customer Partnership”—Our experience and research show that with our Know-How, Customer Collaboration and focus on a Return on Investment (ROI), we can help our customers win in their marketplace better than anyone else. That is our “sweet spot.” The reason we are in business is to not only help our customers meet their project’s stated goals, but to allow our customers to differentiate their products and grow their business.

Our Outcome-Driven Project Cycle

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

CONCEPTDEVELOPMENT

NEXT GENERATION

CUSTOMENGINEERING

DESIGNPROTOTYPE

DEVELOPMENTVALIDATION

& TESTINGMANUFACTURING

& PRODUCTION

CONCEPTDEVELOPMENT

NEXT GENERATION TECHNOLOGICAL ADVANCEMENT

CUSTOMENGINEERING

DESIGNPROTOTYPE

DEVELOPMENTVALIDATION

& TESTINGMANUFACTURING

& PRODUCTION

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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.

ADVANCING TECHNOLOGY

CORE COMPETENCIES

• Concept through Mass Production for Total Life Cycle Support

• Industry’s widest array of proven passive and active thermal

and materials technologies, products and custom solutions

• Next Generation Technology Development and Commercialization

• Collaborative Partnership Business Model

• Multi-disciplinary Engineering and Manufacturing Teams

• Thermal/Mechanical Analysis and Design

• Prototype Development and Qualification Testing

• Pre-production and Mass Production

• Metallurgical Services, including custom metal alloy processing,

testing and characterization

• Quality Commitment Using Lean Six Sigma

• Reliability proven with 40+ years of fielded product in

Mission Critical Systems

• Outcome-driven Project Management

• Global, Vertical Integrated Engineering and Manufacturing Services

Thermacore has a proven track record of developing advanced thermal and material solutions for a variety of applications and markets.

Our Core Competencies include:

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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.

RESEARCH & DEVELOPMENT

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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.

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.

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.

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Fabrication• 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

Specialty Processes• Annealed Pyrolytic Graphite (APG) production with CVD high-

conductivity 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• 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

Quality and Validation Testing• 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

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

Thermacore’s manufacturing capabilities include:

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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.

MANAGEMENT & PERSONNEL

From Concept to Production• Design, Development and Manufacturing of

Advanced Thermal Management and Material Solutions

• Industry and Proprietary Design Tools

• Technology Development of Next-generation Solutions

Qualification/Validation Testing• 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

TOTAL LIFE CYCLE SOLUTIONS

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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).

Engineering Services (Thermal, Mechanical

and Materials)

• 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

Graphite-based solutions• Advanced Solid Conduction:

k-Core® Annealed Pyrolytic Graphite (APG) System

• Thermal Straps, graphite and all metal (aluminum and copper)

Heat Pipe and Other Passive Two-phase- based 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• 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

Thermacore’s product and service capabilities include:

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MARKETS/VERTICALS

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 C3.3Recommended 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

• Aerospace

• Communication

• Computer/Data Center

• Electronics

• Government

• Industrial

• Material Science

• Medical

• Military/Defense

• PetroChemical

• Power Electronics

• Processing

• Renewable Energy/Energy

• Test Equipment

• Transporation/Automotive

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EXAMPLE APPLICATIONSAEROSPACE/MILITARY• 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

COMMERCIALComputer and Data Centers• 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• 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

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info@thermacore.com www.thermacore.com

AS 9100 • ISO 9001 Certified • DDTC/ITAR Registered

LOCATIONSNorth America

Thermacore, Inc.Corporate Headquarters 780 Eden Rd. Lancaster, PA 17601, USA Phone: 717-569-6551 Fax: 717-569-8424

k Technology Division2000 Cabot Boulevard West Suite 150 Langhorne, PA 19047, USA Phone: 215-375-3035 Fax: 215-375-3040

Materials Technology Division440 Jonathan Willey Rd.Belle Vernon, PA 15012, USAPhone: 724-379-1490 Fax: 724-379-1495

Europe

Thermacore Europe, Ltd.12 Wansbeck Business Park Ashington Northumberland, UK NE63 8QW Phone: +44 (0) 1670 859 500 Fax: +44 (0) 1670 859 539

Asia

Thermacore ChinaRoom 1801 North Building Tai Ran Cang Song Mansion No. 6 Tai Ran Road, Fu Tian District Shenzhen

© 2

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Ther

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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

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