Electro Mechanical Assemblies, Twist Capsules, and Cable Wraps supporting Space, Aerospace, and Defense customers.
Supporting Space, Aerospace, and Defense Missions for over 25 years, Cristek has combined deep interconnect design expertise with world-class manufacturing to deliver high-reliability electro-mechanical assemblies for mission-critical platforms. From box builds and cable wraps to complex twist capsules, Cristek provides end-to-end interconnect integration that meets the stringent demands of space, defense, and aerospace systems.
We excel in high-density packaging where complex wiring, electronic components, and mechanical assemblies converge supporting our customers’ most advanced mission architectures.
Lead Time for Catalog Aquila and Orion Series™ Capsules are 8 weeks
CAD Models available Upon request.
Request CAD model or speak directly with a Engineer
When Precision and Reliability Matter
- Performance & Form Factor Upgrades – Spiral development and tighter system integration? We optimize packaging to reclaim performance without compromising reliability.
- Full Traceability & Repeatability – Every assembly is built under controlled documentation, ensuring identical reproduction and full component traceability.
- Strategic Outsourcing – Offload electromechanical subassembly to Cristek to free up internal resources and support supplier diversity goals.
- Design Modernization – Need to update a legacy design with obsolete components? We provide redesign and requalification support to extend product lifecycles.
Twist Capsules (TCA® Series)
A High-Density, Low-Torque Alternative to Slip Rings
Cristek’s Twist Capsules—also known as Twist Caps—are a specialized class of electro-mechanical assembly designed for limited-angle rotational connectivity. When traditional cable wraps or slip rings fall short, Twist Capsules offer a clean, efficient, and robust solution. Each capsule integrates rotor and stator structures with tailored interconnect elements—connectors, cable, and flex circuitry—to enable precise signal or power transfer across a ±175°– 720° range. The result:
- Higher reliability and signal integrity over mission life
- Lower torque and longer service life than slip rings
- Smaller, lighter, and more cost-effective packaging
- Superior noise immunity and mechanical stability
Manufactured in Cristek’s controlled cleanroom environment, each unit is built under strict FOD (foreign object debris) control and quality inspection to meet aerospace-grade standards
TCA® Product Lines
Orion Series™ — Power Transfer and Durability
An effective slip ring alternative engineered for high-current, high-torque applications.
- Up to 5 kW power capacity within a compact aperture
- Up to 111 discrete lines and redundant power pins
- Integrated heat sinking for thermal management
- Ideal for radar, satellite, and EW systems
Hydra Series™ — Signal and Power for Space and Defense
Compact, high-density capsule for signal and low-power applications.
- Up to 740 discrete lines
- Qualified for radiation and vacuum environments
- Supports RS-422, SpaceWire, LVDS, and SerDes interfaces
- Designed for lab, field, and commercial space systems
Aquila Series™ — High-Frequency, Space-Qualified Performance
Cristek’s flagship for high-speed, high-frequency, and fluid transfer in demanding orbital missions.
- Supports data rates up to 15 Gbps
- ±720° rotation range with ultra-low torque
- Up to 80 dB EMI shielding per MIL-STD-461
- Structural, thermal, and radiation analyses per mission profile
- Fully qualified to GSFC EEE-INST-002 Level 2 or higher
Fluid Twist Capsules (FTC Series)
Seal-Free Fluid Transfer for Rotating Systems
Cristek’s Fluid Twist Capsules (FTC-125 / FTC-250 / FTC-375) deliver maintenance-free fluid rotation by twisting qualified PTFE hoses—eliminating dynamic seals entirely.
- No leakage risk with static end seals
- Lightweight, compact, and fatigue-tested to 1M+ cycles
- Qualified to AS2078 / AS604 / AS1339 standards
- Supports pressures up to 300 psi and flows to 3 gpm
Applications include EO/IR systems, gimbals, and thermal control loops where space, weight, and reliability are paramoun.
Why Cristek
- Fully Vertically Integrated – Design, machining, flex, cable, and assembly under one roof (Minden, NV).
- Certified Excellence – AS9100 / ISO9001, ITAR, NADCAP AC7121, IPC-A-610S, MIL-STD-981C compliance.
- Engineering Partnership – In-house electrical, mechanical, thermal, and radiation analysis ensure mission-specific optimization.
- Mission Proven – Trusted on F-35, SPY-6 radar, AIM-9X missile, and SDA LEO satellite programs
Aquila Series™ High Frequency and Transmission: Space Applications
Aquila is Cristek's flagship space-qualified dynamic signal transmission mechanism in the TCA® product line. This mechanism has been designed to meet the performance and environmental requirements for the most demanding space missions. The system can support up to 15Gbps, low torque, and signal counts up to 740 across a +/-200 degree rotational platform.
- Up to 80dB of signal shielding IAW MIL-STD-461
- Proprietary shielding provides cable harness level protection while supporting rotational needs
- Designed to deliver high performance and high reliability for extended on-orbit missions
- Space variant with electronic components screened and qualified to GSFC EEE-INST-002 Level 2 or higher
- Structural, Thermal, Radiation Analyses provided to Specific Mission or Orbital profiles
- Wide array of interfacing configurations and geometry
If you have a rotational package with I/O signals – give us a call to see what we can do for you!
Standard Sizing Options Below - all dimensions are customizable to serve your design
| TCASeriesTM | OD (in/mm) | Aperture (mm/in)Bundle |
| Flex Circuit / or Bundle | Capsule Height (mm/in) | In | mm | In | mm |
| 1 to 8 | 63.5/2.5 | 3.5 | 88.9 | 1 | 25.4 |
| 1 to 20 | 63.5/2.5 | 4 | 101.6 | 1.5 | 38.1 |
| 1 to 20 | 69.85/2.75 | 5 | 127 | 2.5 | 63.5 |
| 1 to 20 | 69.85/2.75 | 6 | 152.4 | 3.5 | 88.9 |
| 1 to 8 | 76.2/3.00 | 6.75 | 171.45 | 4.25 | 107.95 |
| 1 to 8 | 82.55/3.25 | 8 | 203.2 | 5.5 | 139.7 |
| 1 to 8 | 88.9/3.50 | 21.5 | 546.1 | 19 | 482.6 |
| 5 to 20 | 63.5/2.5 | 3.5 | 88.9 | 1 | 25.4 |
| 5 to 20 | 70/2.75 | 4.25 | 107.95 | 1.75 | 44.45 |
| 5 to 20 | 76.2/3.00 | 6.5 | 165.1 | 4 | 101.6 |
| 5 to 20 | 76.2/3.00 | 7.25 | 184.15 | 4.75 | 120.65 |
| 5 to 20 | 82.55/3.25 | 7.5 | 190.5 | 5 | 127 |
| 5 to 20 | 95.25/3.75 | 10 | 254 | 7.5 | 190.5 |
| 5 to 20 | 101.6/4.00 | 12.5 | 317.5 | 10 | 254 |
| 5 to 20 | 108/4.25 | 14.5 | 368.3 | 12 | 304.8 |
| 5 to 20 | 114/4.50 | 21.5 | 546.1 | 19 | 482.6 |
| All capsule heights can use structural members to bridge system interfaces |
| Cells in Grey are directly compatible with Quantic BEI optical encoders sizing |
| Grouping Option - |
| 26/28 AWG copper wire, 34 conductors, rated to 300V |
| 22 AWG copper wire, 10 conductors, rated to 18kV |
| 100 Ω coaxial cable, 8 cables |
| 75 Ω coaxial cable, 8 cables |
| 50 Ω coaxial cable, 8 cables |
| USB 3.0 cable, 3 cables* |
| Fiber Optics, 12 Discrete (MT)* |
Tiered performance Options Below - The Aquila Series is bundled with comprehensive Thermal, Structural, and Radiation Reports. Users can conveniently utilize all available options in the Interfacing and Material Options below.
| Mechanisms | Series |
| Orion | Hydra | Aquila |
| Intended Market | Comm. Space | Comm. Space | Space |
| Certification and Analysis | Yes | Yes | Yes |
| Output Torque (continuous) N-m | .1 - .5 N-m | .2 - 1.0 N-m | Config. |
| Hysteresis Torque | <20%(1) | <10%(1) | <5% |
| Typical Signal Transfer Count | 9 - 111 | 37 - 148 | 37 - 740 |
| Size | Config. | Config. | Config. |
| Vacuum capability | Yes | Yes | Yes |
| Mass | <1.5 kg | <3.5kg | <4.9kg |
| Precision Alignment Need | 1-Axis (Radial) (2) | 2-Axis (Axially) (Radial) (2) | 2-Axis (Axially) (Radial) (2) |
| Low Outgassing | Available | Available | Standard |
| Angular Range | <±125(3) | <±210(3) | <±355(3) |
| Rotational speed | 25°/s | 60°/s | 60°/s(4) |
| Radiation Tolerance krad(Si) | 50 (4) | 50(4) | 100 |
| Lifetime Rotational Fatigue | 1.1E05 - 1E06 | 1.00E+06 | Config. |
| On-Orbit Equivalent for Rad and Fatigue | 1-5 Years on Orbit | 3 - 5 Years on Orbit | 3 - 15 Years on Orbit |
| Max Data Transfer Rate | 5 Gbps | 10 Gbps | 15 Gbps |
| Power Throughput Capacity | .66 - 1.5 kW | >2.7 kW | Config. |
| Operating Temp. (°C) | -40 ~ 80 | -55 ~ 85 | -55 ~ 110 |
| Storage Temp. (°C) | -60 ~ 90 | -60 ~ 90 | -60 ~ 90 |
| Notes | (1) The torque profile is primarily shaped by geometric factors, whereas in a motor-driven system, this aspect assumes a diminished significance. |
| (2) System Level Alignment depending on interfacing |
| (3) Range can be reduced or increased depending on application to reduce weight and increase signal performance |
| (4) Can be adjusted for mission performance trades with shielding weight |
Supported System Transmissions
Cristek’s Twist Capsule Assemblies (TCA®) enable seamless signal, power, and data transmission across dynamic rotational interfaces. Whether used in payload-to-payload connections, missile interconnects, or payload-to-bus transfers, Cristek delivers robust interconnect performance for mission-critical systems operating in the most demanding environments.
Our solutions support a wide range of payload applications, including PMAs, cameras, LaserCom systems, sensors, and guidance electronics, ensuring stable and precise connectivity throughout your platform’s life cycle.
System Architecture Elements Supported
- Gimbal Heaters
- Solar Arrays
- Sensors and Gyros
- PSD (Position Sensing Devices)
- Encoders (e.g., Quantic BEI)
- Camera Protocols
- Motors and Resolvers
- Focus Mechanisms
Interface Standards Supported
- LVDS (Communication, Control, Clock, Data)
- RS-422 and Digital I/O
- Power + / - distribution channels
- SpaceWire data protocols
- LaserCom optical transmission
- SerDes serial data links
Cristek supports both standard and custom interface protocols, enabling full compatibility with aerospace, defense, and space-grade subsystems. Our interconnects are engineered to maintain signal integrity and timing stability with rise/fall times of 200 picoseconds, meeting the performance requirements of modern high-speed data systems.
Mission-Ready Integration
From initial concept through qualification, Cristek engineers design and validate complete interconnect architectures that align with your mission’s signal, thermal, and structural requirements.
Whether you’re transmitting high-speed digital signals or high-current power lines, Cristek ensures your system operates with reliability, precision, and minimal noise degradation.
Pick your system architecture elements and Cristek will take it from there!
Our engineering team will tailor your design for optimal signal, power, and mechanical performance across every degree of motion.
Capabilities