Custom engineering.
Sole-source from concept to production. CAE design, machined, welded, polished, and inspected in-house in Carson City. Custom assemblies have been Aquasyn's forte since 1996.
Recurring product lines · and everything in between.
Aquasyn's custom engineering team builds across the categories below as routine work, and regularly takes on bespoke requests that fall outside all of them. Call us when you need it done right and on time, the first time.
Custom Tees and CPMs
Custom tee bodies and contact pressure manifolds machined to specific flow geometries, port counts, and dimensions. Built on the Zero Static block-body platform with full traceability.
Custom Manifold Assemblies
Multi-valve manifold assemblies machined from block, with custom port configurations, drain paths, and station counts. Configurable across actuation modes and diaphragm materials.
Custom Dip Tubes
Reusable stainless dip tubes for sampling, transfer, and addition operations on bioreactors, tanks and process vessels. Length, diameter, tip profile and end connection built to the specific vessel and process step.
Hose Racks & Hose Hangers
Stainless hose racks and wall-mounted hose hangers for hygienic process environments. Hangers keep transfer hoses off the floor and draining between uses; racks are configured for cleanroom layout, drainage, and the tubing or assembly count being stored.
Pump Carts & Carboy Carts
Portable pump carts that move a transfer pump, its controls and hoses between suites for flexible manufacturing, and transport carts for carboy handling. Sized to the equipment footprint and the facility's ergonomics, built with the same in-house fabrication and finishing as the rest of the line.
Custom Filter Housings
Hygienic filter housings machined and welded in-house, sized to the cartridge spec and the process pressure rating. T-style and in-line configurations, electropolished interior, hygienic end connections.
Bioreactor & Tank Spargers
Bioreactor, micro, static, and tank/in-line spargers built to the vessel geometry and the gas-transfer requirement. Drilled-hole, frit, and sintered-element designs in 316L or higher-alloy stainless.
CPM Pressure Manifolds
Contact pressure manifold assemblies with integrated pressure-gauge or pressure-sensor ports, machined from block. Drains, vents, and instrumentation taps configured per the process P&ID.
Hygienic Thermowells
Stainless thermowells that put an RTD or thermocouple into the process without opening the line, sized to the probe diameter and insertion length. Hygienic clamp or weld-in connections, with the product-contact surface finished to the same spec as the line it sits in.
Spool Pieces & Flange Adapters
Tube spools built to drawing, including flange-to-clamp transitions for tying hygienic tubing into flanged vessels and equipment. Bends, branches and end connections to the line's isometric, welded and finished in-house.
Tri-Clamp Adapters, Reducers & Hose Fittings
The fittings that aren't in a catalog: odd-size clamp reducers, clamp-to-hose-barb adapters, and custom hose fittings for transfer lines and hose assemblies. Machined from 316L bar stock with the same MTR traceability as the valve line.
Truly bespoke builds
Customized and hybrid valve assemblies for unusual applications have been Aquasyn's forte since 1996. If it doesn't fit the categories above, it's likely still in scope · just send the sketch.
Concept · drawing · production · delivered.
One engineering team owns every step. No contract manufacturing, no third-party welding shop in the middle. Sole-source from the first sketch to the inspected, finished assembly leaving Carson City.
CAE design
Five-axis-ready 3D modeling in SolidWorks and AutoCAD. Engineering reviews the process context and proposes the geometry that solves it.
Detailed for review
Fully detailed drawings shared with the customer for review and approval before any material is touched. No production starts without sign-off.
In-house craft
Machining on five-axis centers to ±0.005″, welding, polishing (ID, OD, electropolish), assembly, all under one roof. Skilled craft persons across every station.
Inspected & documented
Final inspection, EN 10204 3.1 MTRs with heat numbers as standard, and shipped from Carson City. Weld logs, weld maps and finish records are available on request.
Design and production · under one roof.
The capabilities a custom hygienic build actually needs · design, machining, welding, polishing, and electropolishing · all in-house. Aquasyn doesn't subcontract any of them.
Design capabilities
- High-end CAE design · native STEP and IGES formats
- SolidWorks & AutoCAD · standard modeling environments
- CAD/CAM software · model to G-code under one workflow
- Fully detailed drawings for customer review and approval
- Rapid customer turnaround with concepts, drawings, and production
- Special end connections, configurations, and materials by design
Production capabilities
- 5-axis machining centers · ±0.005″
- Orbital welding · automated and manual
- Polishing · ID, OD, and electropolishing in-house
- High-volume production capability
- Expert fabrication, welding, and polishing by skilled craft persons
- Products made in the USA · Carson City, Nevada
Exotic materials are an Aquasyn specialty.
When 316L isn't the right answer · chloride exposure, aggressive chemistry, extreme temperature, regulatory pressure · Aquasyn has been machining the alternatives since 1996.
Where Aquasyn custom engineering does the work.
Custom builds specified across high-purity processes where off-the-shelf valves cannot meet the engineering, validation, or geometry requirements.
Send the sketch.
If you can describe the assembly, Aquasyn engineering can design, machine, weld, polish, and deliver it. Rapid customer turnaround is standard. Exotic materials a specialty.