aerospace, defense, and space solutions

AEROSPACE, DEFENSE,
AND SPACE SOLUTIONS
WIRE HARNESS
SPIRAL WRAP – This product is an expandable,
highly flexible wrap for harnessing and insulating
wires, cable, hoses, and other bundles. It is available in a
variety of high-performance materials. ASTM D 3295 certification is available upon request.
CONVOLUTED – Convoluted tubing, commonly referred
to as flexible conduit, can be used to house multiple wires
to prevent chafing. The material can be drilled with holes
to act as drain passages or marked with part numbers and
slit to easily wrap and protect wires. 81914 certification or
special sizing is available upon request.
HEAT SHRINK – Heat Shrink tubing provides a state-of-theart method for the application of a tight, protective covering to items that will be subjected to the extremes of heat,
corrosion, shock, moisture, and other critical environmental
conditions. Zeus manufactures high-performance Heat
Shrink tubing in a variety of polymer resins, including PTFE,
FEP, PFA, PEEK, ETFE, PTFE/FEP Dual-Shrink® & NeoTemTM.
These high temperature shrinkable products have expansion ratios from 4:1 to 1.2:1. 23053/11 & 12 certifications are
available upon request. Specialized heat shrinks are also
available, such as Dual-Shrink® & PEEKshrink®.
DRAWN FIBER - PEEK, PFA, FEP, ECTFE, PVDF, ETFE, and
Aeos® ePTFE all make excellent braiding materials for cables
that increase chafe resistance while minimizing weight.
Tensile elongation and shrinkage can be customized for
specific braiding applications.
CUSTOM EXTRUSIONS - Spline shapes commonly center
wiring while reducing vibration impact and allowing air/
moisture passage. Other specialized shapes provide individual isolation of wires in multiple lumens.
FIBER-OPTIC
SPECIALIZED EXTRUSIONS – Zeus holds
machine grade tolerances (~0.001”) on
plastic tubing used in fiber optics. FEP, PTFE, THV, PEEK,
NeoTemTM or ETFE are typical performance resins utilized
for fiber optic extrusions. Fillers, such as glass, can be
introduced to increase the robustness of items while
maintaining the smooth bore of the furcation tubing.
Engineered Surface tubing reduces friction and drag
force by extruding micro-structured channels on the
inside, outside, or both tube walls.
Annealing options are available to reduce the coefficient
of thermal expansion in plastics at high temperature
ranges. Convoluted products can act as a conduit for the
delicate fibers, reducing vibration impacts and chafing.
Aeos® ePTFE, also known as expanded Teflon®, can be delivered as a flexible sheathing that will maximize flexibility
while reducing signal loss or distortion in the fiber.
FLUID MANAGEMENT
FILLERS – Carbon can be utilized as a filler,
which can be added to PTFE or melt extruded resins in order to increase static dissipation for fluid
management applications. Dual-layered extrusions or
homogeneous extrusions are available. Custom percentages and other unique fillers can also be introduced along
with technical consultation on finding a resin that will increase barrier properties in critical applications.
TUBING – Zeus can customize the tolerances or wall thickness upon request to increase burst pressure. Lengths can
be continuous or cut for kitting options. Zeus’ performance
tubing offerings are chemically inert to typical aerospace
HEAT SHRINK RELEASE AIDS – FEP, ETFE, fluids such as JP fuels, Skydrol, De-icing and Salt Spray.
PEEK and PTFE are approved contact resins for
composites. Zeus can make Sub-Lite-Wall® (~0.004”) heat FIBER – Zeus’ Drawn Fiber can also help increase the burst
shrinks that offer seamless coverings to composite forming pressure of hoses through customizing the fibers’ tenacity
mandrels or bladders that expand with heat and pressure for for braiding applications. Many of our offerings, such as
composite manufacturing. These innovative heat shrinks PEEK, can be delivered to a braider of choice to increase
replace labor intensive film or tape, saving labor time and the end performance of fluid hoses while reducing weight.
allowing a better finish on the end composite part.
COMPOSITE FORMING
NEOTEMTM | PTFE | FEP | PFA | ETFE | PVDF | PEEK | ECTFE | THV | MFA | NYLON | HDPE | LDPE & MORE
ACCELERATE PERFORMANCE
MOTOR/MAGNET WINDING
Weight Reduction – Replace heavy metals
PEEK Insulated Wire has excellent
with performance plastics such as PEEK,
dielectric properties of over 3000 volts/
which has one of the highest strength to weight ratios of mil, 500°F/260°C thermal endurance and extreme
any thermoplastic. Product lines include: Convoluted, abrasion resistance. These products are commonly
Spiral Wrap, Heat Shrink, Insulated Wire & Custom Profiles. utilized in motor winding applications as a superior
seamless wire insulation that drives motor performance.
Temperature Extremes – Advance electrical designs by utilizing NeoTemTM as the insulation of choice. NeoTemTM has Round, solid, stranded, square, and rectangle profiles are
great electrical properties at elevated temps. (300oC/572oF). all available wire coating options for PEEK. Zeus extrudes
over many conductors including, but not limited to copper,
Radiation – PEEK as well as PVDF are excellent materials silver-plated, and nickel-plated materials. PEEKshrink®
for space components or other areas where radiation is another product often utilized to splice Zeus PEEK
resistance is needed to accelerate performance.
Insulated Wire. Additional wire coatings in PTFE, PFA,
ETFE, NeoTemTM or FEP are available for designs. Zeus
Reduce Friction - Engineered Surface tubing allows also has the ability to work on custom extrusions over
easier pushing/pulling of wire into harness assemblies wire to increase insulation needs in creative ways.
or decreases friction and strain on fiber optic sheathing.
TUBING OPTIMIZATION
VALUE-ADDED SERVICES - Zeus has an
impressive array of optimized tubing
solutions for advanced applications. By having Zeus
perform value-added services and operations, our customers have recognized increased economies of scale,
improved yields and manufacturing efficiencies.
DRILLING OR CUTTING – Custom cutting allows kitting
of parts while drilling can allow for air/fluid passage.
HEAT SHRINKING OVER MANDRELS – Zeus can
perform light assembly and can heat shrink tubing
onto parts and subcomponents.
MIL-SPEC GUIDE
ASTM D 3295
PTFE Tubing & Monofilament,
Beading & Spiral Wrap
AMS 3653, 3654 & 3655
PTFE Wire Gauge Tubing
MIL-I-22129
PTFE Standard Wall Tubing
ASTM D 3296
FEP Tubing
AMS-DTL-23053/12
PTFE Heat Shrink
AMS-DTL-23053/11
FEP Heat Shrink
AMS-T-81914/1-6
PTFE, FEP & ETFE
Convoluted Tubing
A-A-59602
PTFE Spiral Wrap
CUSTOM ETCHING – Etching reduces the surface
lubricity of plastics and increases ability to bond.
CUFFING – Zeus’ PTFE convoluted can be cuffed to
provide a smooth surface to attach fittings.
PART MARKING - Laser etching or pad printing enables
custom printing of graphics, logos and text to identify parts.
CONTACT ZEUS AT 1.800.526.3842 FOR SAMPLES OR TO REQUEST A QUOTE.
RESEARCH & DEVELOPMENT
NEW DIMENSIONS IN MATERIAL SCIENCE - Zeus
is a material science company that creates breakthroughs in the aerospace industry. Our team places
a premium on collaboration with partners through
our Research & Development division. Zeus R&D is
at the forefront of the developing advanced polymers and custom products for demanding applications, filled polymers for static dissipation, or
customized options that allow conductivity.
• ISO 9001:2008
• Six Sigma-Certified Black Belts on Staff
• Polymer Selection/Contract Research Available
• Global Tech Support
• Multiple Manufacturing Facilities
GLOBAL LOCATIONS
North America | (P) 1 (803) 268-9500 | (F) 1 (803) 533-5694
Asia | (P) 86-13922204986 | (F) 86-13922204986
Europe | (P) 353-0749109700 | (F) 353-0749160051
Latin America | (P) 1 (803) 268-9500 | (F) 1 (803) 533-5694
3737 industrial Boulevard | Orangeburg, SC 29115 USA | www.zeusinc.com