Manufacturing & Quality — Apex Thermal Systems

210,000 sq. ft. Production Facility

Our headquarters and primary manufacturing campus in Phoenix, Arizona is purpose-built for thermal infrastructure production. The facility houses precision CNC machining, automated tube bending, cleanroom assembly, pressure testing, and full electromechanical integration under one roof.

We maintain a second manufacturing line in Dallas, Texas for geographic redundancy and faster East Coast deployment. Both facilities operate under unified quality management and ERP systems.

ISO 9001:2015 certified quality management
ISO 14001 environmental management
UL 508A and CSA C22.2 panel shop certification
AWS D17.1 certified welding program
ITAR registration for defense programs

Core Manufacturing Capabilities

Vertically integrated production from raw material to finished system

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Precision Machining

5-axis CNC machining centers for manifolds, valve bodies, and custom fittings. Tolerances to ±0.0005" on critical sealing surfaces. Materials include 316L stainless steel, aluminum 6061-T6, and brass C360.

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Tube & Hose Fabrication

Automated tube bending up to 3" OD with mandrel support for wrinkle-free bends. In-house crimping, welding, and pressure testing. Custom hose assemblies with braided stainless or polymer overbraid.

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Welding & Brazing

TIG, MIG, orbital, and vacuum brazing capabilities for stainless steel, copper, and aluminum joints. AWS D17.1 aerospace welding standards applied to all critical coolant path joints. 100% helium leak testing.

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Electromechanical Integration

UL 508A certified panel shop for CDU controls, power distribution, and monitoring enclosures. Programmable logic controllers, VFDs, and smart sensor networks integrated and tested before shipment.

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Pressure & Flow Testing

Hydrostatic testing to 1.5x working pressure. Helium mass spectrometry for leak detection to 1×10⁻⁹ mbar·L/s. Automated flow balancing and thermal performance validation on every CDU and RDHx.

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System Assembly & Burn-In

Cleanroom assembly for fluid path components. 24-hour minimum burn-in at design load for all CDUs. Thermal cycling and vibration testing per IEC 60068. Pre-filled and sealed systems shipped ready to connect.

Quality Management Systems

Documented, traceable, and auditable at every stage

Incoming Inspection

All raw materials and purchased components are inspected against material certifications, dimensional drawings, and functional specifications. Rejected lots are quarantined and dispositioned within 24 hours.

In-Process Control

First-article inspection on every production run. Statistical process control (SPC) on critical dimensions. Real-time shop floor data collection with automatic alerts when processes drift from control limits.

Final Acceptance Testing

Every CDU, RDHx, and dry cooler undergoes a documented factory acceptance test (FAT) before release. Test reports include pressure hold, flow rate, thermal performance, control response, and safety interlock verification.

Quality Metric	Target	2024 Performance
First Pass Yield	> 98.5%	99.1%
On-Time Delivery	> 95%	97.3%
Customer Complaint Rate	< 0.5%	0.2%
Supplier PPM	< 500	320
FAT Pass Rate	100%	100%

Certifications & Compliance

Meeting global standards for safety, performance, and environmental responsibility

ISO 9001

ISO 9001:2015

Quality management system certified by TÜV SÜD. Annual surveillance audits with zero major non-conformances since initial certification.

ISO 14001

ISO 14001:2015

Environmental management system covering waste reduction, energy efficiency, and responsible material sourcing across both facilities.

UL 508A

UL 508A / CSA

Industrial control panel shop certification. All electrical assemblies carry UL or cUL label for compliance with NEC and CEC requirements.

ITAR

ITAR Registered

Registered with DDTC for defense and aerospace programs. Facility security and export compliance procedures in place for controlled technical data.

Rapid Deployment Capacity

Scaled production for urgent AI infrastructure timelines

Warehouse with racked systems ready for shipment

Current Monthly Capacity

Our combined facilities can produce up to 400 CDUs, 1,200 RDHx units, and 50 miles of custom hose and manifold assemblies per month. This capacity is being expanded with a third line in 2025 to meet accelerating demand from AI data center deployments.

Expedite Programs

For customers with critical timelines, we offer expedited production with dedicated work cells and extended shifts. Typical expedite lead times:

Standard CDU: 8–10 weeks → 4–5 weeks expedited
Standard RDHx: 6–8 weeks → 3–4 weeks expedited
Quick disconnect kits: 2–3 weeks → 1 week expedited
Custom manifold assemblies: 4–6 weeks → 2–3 weeks expedited

Supply Chain Resilience

Dual-sourcing, strategic inventory, and North American supplier network

Dual-Sourcing Strategy

Every critical component has at least two qualified suppliers. Alternate sources are validated with full incoming inspection and first-article approval before being added to the approved vendor list.

Strategic Inventory

We maintain a 90-day buffer stock of long-lead components including pumps, heat exchanger cores, and specialized valves. Safety stock levels are reviewed monthly based on demand forecasts and supply risk.

North American Supplier Base

Over 80% of our purchased materials are sourced from North American suppliers. This reduces shipping lead times, simplifies logistics, and minimizes exposure to international tariff and customs delays.

Manufacturing Excellence