With the 1.5 GHz couplers for VSR DEMO are now in the manufacturing stages, the studies that led to the final coupler design will be presented. The system specific constraints and design modifications that combat the challenges of; thermomechanical stresses, HOM propagation and dimensional constraints are explored. This includes S Parameter analysis, an in depth study of the coupling factor, and multipacting studies for the average 1.5 kW and peak 16 kW powe