Gas Box / Gas Cabinet Experts
Axenics has more than 35 years of experience in building gas boxes, gas cabinets, gas manifolds and gas panels for a variety of industrial applications. Through our work with a diverse group of companies in a range of industries, we have found that the terms “gas box” and “gas cabinet” are interchangeable.
Our experienced engineers and supply chain experts work directly with customers and materials suppliers from the initial design phase through manufacturing and delivery.
A gas box not only contains the gas itself but also house the controls and sheet metal to protect the gas panel as well as the surrounding environment. There is also room inside the gas box for gas canisters and cylinders. Gas boxes protect people from exposure to potentially harmful gases.
We take every precaution to ensure that a gas box is built to specifications precise to the manufacturing operation, while making sure to use materials and components that are suitable to the characteristics of each gas.
Benefits of Gas Manifolds in Semiconductor Gas Delivery Systems
The uses for semiconductors in electronic devices grow by the minute, maintaining a high demand for components such as chips for automobiles. For many of our customers, we produce manifolds that are used in either the production of semiconductors or for use inside the semiconductors themselves.
One of the most-important determinations for semiconductor assembly is if the components transport potentially harmful and corrosive chemicals in the form of gases or liquids. If so, we often recommend the use of gas manifolds in the delivery system, which provide a number of benefits, including fast production.
Producing gas manifolds with a leak-tight performance – tested each step of the way – is how we ensure our customers are getting reliable, safe, long-lasting components.
The gas delivery systems created by Axenics’ team of cross-trained technicians are all custom configurations based on our clients’ designs (our team can also assist in the design phase). We typically use Vacuum Coupling Radiation (VCR) metal-to-metal seal connections to ensure that leaks are not an issue.
The manifold systems we build for gas or chemical delivery are all completed with dry processes. The systems have zero exposure to moisture, until the system passes testing and is installed. The only liquid exposure, once installed, would be the chemicals designed to flow through the system. We use in-house processes to keep residual chemical liquids from building up within the system once in use.
Our capabilities to produce custom gas delivery systems include systems that get heated. Based on our customers’ designs and configurations, we have built heated systems using a special tape wrapped around the tubing and valves. This tactic can keep the system heated to the point where chemicals are not able to solidify while in transfer.
Benefits for using gas manifolds for your next semiconductor project include:
- A smaller footprint with less hardware
- Option to expand and add additional gas manifolds/lines at a later date
- Quick assembly
- Shorter time when checking for potential leaks
- Custom fittings that work with your set-up
- Simple maintenance
- Light and easy to install into your existing system
- A centralized manifold system gives you better control
- Designed for consistent, repeatable use
- A cleaner system overall
On the latter, when creating components for semiconductors, cleanliness is of the utmost importance. No one wants to worry about particles that end up in your processes from vendors who do not take cleanliness seriously enough.
A critical factor in performance for precision gas delivery in semiconductor processing is the reliability and repeatability of the transportation system, especially with such processes as chemical vapor deposition.
When you work with our team on your specific goals for the system, we can predict the quality of these components before construction, helping you eliminate potential problem points.
When you’re provided with a centralized manifold-based gas system, you’re in an ideal place to maintain control over the gas or chemical output, rate and pressure. For each of your gas delivery systems, you can rest assured that they are expertly designed, engineered, assembled and tested by our cross-trained team of experts.
Keeping a consistent, speedy workflow on your floor with an in-house gas delivery system ensures your customers will be completely satisfied with the results of the semiconductor components you deliver.
A Gas Box Speeds Your End Results
The demand for high-quality, complete gas delivery systems continues to rise as advancements grow in a variety of industries, such as medical devices, semiconductors and alternative energy.
A gas box can give your team a centralized location for gas cylinders and regulators, as pipelines push gases to output locations throughout your multiple workstations. Having a centralized gas system in place offers you better control over the gas output, rate and pressure.
We can provide you with a gas delivery system while ensuring the entire system is designed, engineered, assembled and tested by our team of experts. Once you receive it, the gas box is ready for installation.
There are benefits to having us create a complete gas cabinet solution for your production floor:
Complete Systems Save You Money & Get You to Market Faster
Some OEMs choose gas cylinder rentals, but rental prices will rise over time. Plus, you’re at the mercy of the rental facility, and you are potentially losing money while waiting for the replacements for empty gas cylinders.
Gas boxes manufactured by Axenics provide you with an efficient way to deliver gas through your systems. Implementing an in-house system means gas cylinder changes are convenient and won’t disrupt workflow on your production floor. With in-house engineering and design experts, we will help you determine the right type of gas delivery system based on your goals.
If your operation is growing, you’re likely already aware that adding components one at a time results in stretching your completion dates. Rather than purchase and install gas box components piecemeal, let us assemble a full gas box system for your current – and upcoming – needs.
We continually stock many common parts and fittings for gas cabinets, and our strong relationships with vendors will allow us to build a gas box system for you at a reasonable cost to you, no matter what components are necessary.
Cross-Trained for Expert and Safe End Results
Our employees are cross-trained for every aspect of a gas box build:
Another element to consider, you may need a gas monitoring system if you’re using toxic or flammable gases as they can sometimes build up in an enclosed room. We can assemble this system for you.
Safety is of the utmost importance when it comes to installing a gas box system. The end product we deliver to you has reached or surpassed every safety guideline.
Gas Panels Built to Specification
Gas panels are built to customer order specifications and designs. With in-house engineering and design capabilities, we help our customers determine the right type of gas panel based on what they are trying to accomplish, and then build what you need – valves, regulators, pipes, controls, etc.
Gas panels can be installed inside gas boxes or can be independent of the gas tanks/cylinders. Gas panels are relatively simple devices while gas cabinets are more complex.
Axenics is well qualified to build efficient handling systems for gas, liquid and chemical delivery. We build custom sub-assemblies of complex gas boxes designed to fit your specific needs. We are dedicated to providing an end product that is of superior quality and that it is also delivered on time and within budget.
Gas Cabinet Safety
To address gas cabinet safety concerns while also providing a centralized delivery system, gas panels and gas cabinets can provide an efficient way to deliver the right amount of gas to each workstation. In addition, implementation of these systems allows for gas cylinder switch-outs to happen more conveniently, with less disruption to the production floor and reducing the number of canisters taking up space. Here are some characteristics of certain gases that you may choose to use in a gas cabinet, as well as the types of gas delivery components that work best for safety:
Toxic and poise gases
OEM Biomedical Companies Finding Benefits When Investing in Gas Boxes
Working in the life sciences and biomedical industries requires creating the tools needed to perform research and provide healthcare services. Designing medical and biomedical devices require attention to detail and precision to ensure that the tools are up to required standards.
When performing welding services, having the right amount of gas delivered to the station allows technicians to complete the job by specified deadlines. However, the more workstations in the fabrication department, the more gas used in an application. There is nothing worse than having a technician almost complete their part of the fabrication process when suddenly the gas cylinder empties. A job completed in 2 minutes must now take another 30 minutes as a new gas cylinder must be fitted and to have the regulator adjusted for the right pressure and flow. Now imagine that this scenario happens with multiple workstation locations in the factory, or several technicians who may require more pressure and flow to their gas supplies.
With the rise in costs in gas cylinder rentals and lost productivity, this can impact the medical device output for OEM companies. Gas boxes provided by Axenics accomplish a more efficient method for gas delivery at multiple stations.
Gas Boxes Delivering Uninterrupted Supply for Every Application
Axenics provides OEM biomedical companies with customized design, engineering and manufacturing of gas boxes for their factories. Gas boxes will allow you to have a centralized location for your gas cylinders and regulators as pipelines run to output locations at multiple workstations. This setup provides greater control over gas output, rate and pressure. When the main gas cylinder supply runs low and drops below a specified PSI setting, the reserve cylinders are accessed through the regulator. So technicians can continue working uninterrupted to complete the application.
Multiple Gas Manifold Types Available
Every OEM company has different gas supply needs and will desire a manifold system that offers the type of control they want. Axenics can create customized gas boxes that more align to your specifications. There are several different gas manifold systems you can select:
- Manual Switchover: Multiple cylinders placed into the manifold with an outlet that has a pressure-reducing regulator. These systems require constant monitoring to switch out used cylinders.
- Primary/Secondary Reserve Switchover: You have a main bank of cylinders in operation and a secondary reserve bank of cylinders. Each bank feeds into the line as the main cylinder reserve is normally set at a higher PSI than the secondary reserve. When gas delivery supply drops below the set PSI, the secondary reserve cylinders begin feeding the system as the depleted cylinders from the main bank get replaced.
- Fully Automatic Switchover: These switchover systems are more automated as the manifold uses pressure sensors to monitor the gas supply until it reaches a predetermined pressure setting. Then the system will close off the main supply bank regulator and use the reserve bank.
- Semi-Automatic Switchover: Some semi-automatic systems can be set with two pressure settings for the main supply bank, a high setting (such as 300 psi) and a lower setting of 100 psi. Then the secondary reserve bank can be set at 200 psi. When pressure drops below 300 psi for the main bank, the regulator will automatically open to let the secondary gas supply bank to feed the system. A technician can then use a lever to switch the main cylinder bank to the lower 100 psi setting. Once the secondary reserve cylinders drop below 200 psi, the main cylinder supply is re-accessed.
Better Monitoring of Gas Supply Provided by Axenics
As operations grow bigger, your gas supply needs increase. Axenics’ gas delivery systems can help biomedical OEM companies better track their supply consumption. They can monitor the number of cylinder change-outs based on the application. Then they can rent the appropriate number of cylinders as well as determine other cost-effective ways to perform certain welding applications.
Since gas boxes allow for all technicians to use the same gas supply, you can more efficiently use up a single gas cylinder at a time without having half-full canisters scattered throughout the facility. Biomedical companies can reduce safety hazards with fewer cylinders scattered around the facility as they reside in just one location.
Choosing Pipes for a Gas Box
Axenics is always looking for ways to improve your product. Once we receive your design for a gas box, our team might see a better way to utilize pipe bending in the project, to save space, time and money. Here are some questions to ask when deciding on the best type of pipes to install into your gas box:
Is the Material Compatible with Gas?
Certain materials impact the properties of the gas. The pipe could corrode faster, become brittle and crack apart, or cause contaminants to leak or leach into the gas cylinder.
What Pressure Rating is Required?
Certain pipe and tube materials are only rated to withstand specific pressures before experiencing failure. Pipes come with a pressure rating that signifies the amount of pressure they can withstand before bursting or cracking. For example, copper pipe may have a pressure rating of type L, which indicates that they can withstand gas pressures of up to 200 pounds per square inch gauge (PSIG).
How Important is Gas Purity?
For certain applications, such as manufacturing semiconductors or medical devices, the purity of the gas used is essential. The piping needs to have a certain thickness, when the pipe is welded together. One type of pipe material used to ensure high purity gas applications is stainless steel with an electro-polished interior. A manufacturer may also select copper tubing or plastic tubing when they do not want a hard pipe or seams.
How Hot is the Gas?
Some gases may have extreme hot or cold temperatures, such as cryogenic gases that have a boiling point of negative 130 degrees Fahrenheit. These gases can cause the wrong type of pipes to break or burst. The material selected has to withstand extreme temperatures. A manufacturer may also have to select a material that prevents temperature fluctuations since some gases can spontaneously combust (pyrophoric gases) when there is a change in temperature.
Which Sterilization Method is Best?
Sometimes a pipe must undergo sterilization to remove contaminants and ensure the highest purity gas goes through the line. Selecting gas cabinet piping requires understanding how the pipe will react to certain cleaning methods. If a clean in place (CIP) sterilization method happens where chemicals are inside the pipe, the pipe materials must be able to withstand the chemicals and not corrode. If using a steam in place (SIP) method, the pipe material must be able to withstand the steam’s high temperatures.