Vertically Integrated Manufacturing for Quality and Reliability
Lytron's 115,000 ft2 (10,700 m2) manufacturing facility in Woburn, MA and 10,000 ft2 (930 m2) manufacturing facility in Changzhou, China are designed to be flexible and agile for maximum throughput of custom cooling systems and components. Lean manufacturing principles, vertical integration, and cellular organizational structure make this possible.
Our in-house manufacturing and test capabilities include:
- Systems assembly with several lines dedicated to custom liquid cooling products
- CNC machining, EDM, CNC tube bending, and high-speed fin making
- Advanced metal joining including torch brazing and TIG welding
- Vacuum brazing, including an environmentally-controlled room, multiple vacuum furnaces, and a heat treat furnace
- Quality Assurance (QA) testing in our well-equipped QA lab which includes Coordinate Measuring Machines (CMMs), hardness testing equipment, an optical comparator, and photo-micrograph capabilities
- Performance testing in our extensive engineering lab, which includes wind tunnels, test stands, flow meters, leak detectors, and much more
Since all performance-critical processes, such as fin-forming, machining, vacuum brazing, and tube bending, are carried out in-house, we can guarantee that your product will perform as predicted. Equally important, production is in the same facilities as our designers and our engineering test laboratories. As a result, we maintain control from initial concept to completion, so you can be sure that all products are built exactly as the engineers intended.
Our manufacturing strategy focuses on optimizing manufacturing processes and continuous improvement through employee involvement. We are ISO 9001 and AS9100 certified and utilize Six Sigma and zero-defect manufacturing for the highest quality products and the fastest delivery. Our investments in capital equipment have enabled us to increase production capacity, reduce costs and lead times, and produce the highest quality products. Our self-managed work cells take full responsibility for product quality, on-time delivery, and cost reduction efforts.
In addition to ISO 9001:2008 and AS9100:2009 certification, Lytron’s quality program conforms to military inspection standard MIL-I-45208A. Lytron maintains a welding program with operators certified in accordance with Navsea S9074-AQ-GIB-010/248, SAE-AMS-STD-1595, and AWS D17.1. Vacuum furnace and torch brazing processes are performed in full compliance with ANSI/AWS C3.7.
In our engineering laboratory we can test any cooling system or component that we manufacture in order to validate designs or test finished product. Our well-equipped, in-house test facility includes wind tunnels (up to 21,000 ft3/min or 594 m3/min), an IGBT/cold plate test stand, system and system component reliability test stands, an environmental test room, refrigeration test equipment, a vibration test stand, particle counters, microstructure analysis system, and various flow, temperature, and pressure instruments.
To support our fast growing chiller
and cooling system
business we have multiple production lines. Our newest Woburn, Massachusetts cooling systems assembly line
produces large, full rack size liquid cooling systems. The U-shaped line, consisting of three balanced work stations and two test stations, is designed for single piece flow on specially designed dollies. The advantages of this layout are flexibility among operators, improved operator communication, and a controlled-flow pull process. Lytron's systems lines include:
We have multiple vacuum brazing ovens, one of which can accommodate cold plates and heat exchangers up to 10 ft (3.05 m) long. Lytron vacuum brazes thousands of parts per year. Prior to vacuum brazing, cold plates and heat exchangers are assembled in an environmentally controlled room for maximum yields, cleanliness, and quality. Lytron’s computer controlled vacuum brazing process and unique, robust fixture designs ensure strong and reliable metal joining that meets the demands of both commercial and military customers.
In our Woburn quality assurance lab we have two coordinate measuring machines (CMM) for inspecting cold plates, chassis, and heat exchangers. We can inspect parts up to 10 ft (3.05 m) long with measurement accuracies of 0.0001" (0.003mm). CMM's are used in manufacturing to inspect a component or assembly against the design specifications. Lytron performs all mission critical processes in-house, including quality inspections of all custom designed and built components. With our capabilities, we can ensure the highest quality inspections and the highest quality parts. (Review our Quality Statement and ISO 9001:2008 / AS9100:2009 Certificates.)
Our manufacturing strategy focuses on optimizing manufacturing processes and continuous improvement through employee involvement. Lytron's investment in capital equipment for our production lines has enabled us to increase production capacity, reduce costs and lead times, and make high quality products in less time. In addition, self-managed work cells take full responsibility for product quality, on-time delivery, and cost reduction efforts.
Lytron designs and manufactures cold plates, cold plate assemblies, cooling systems, heat exchangers and heat exchanger assemblies for OEMs and end-users around the world.
Learn about Lytron's engineering department, which provides custom product design as well as expertise in Design-for-Manufacturability (DFM).
Watch our Facility Tour