Custom Solutions

Custom solution

Aviation

For filling oxygen cylinders on site, we develop automated systems that control pressure, flow and the filling sequence reliably and reproducibly.

Pressure controlautomatic

Data loggingintegrated

Custom solution

3D printing

For all 3D printing processes (e.g. laser sintering and WAAM), shielding gases can be supplied in a targeted way and relevant atmosphere parameters such as residual oxygen and moisture can be monitored continuously – both in the gas supply and in the build chamber.

Mixing and measuring rangeppm to %

Flow rate0–5,000 ln/min

Custom solution

Microelectronics

Defined forming and process gases and controlled inerting support stable conditions in sensitive manufacturing processes.

Measuring rangeppm to %

Residual moisturefrom 0.1 ppm

Custom solution

Art

From defined helium mixtures for floating installations to monitored atmospheres for sensitive artworks in display cases and storage depots, we develop individual solutions for art and stage technology.

Mixing ratiosfreely configurable

Monitoringcontinuous and documented

Custom solution

Grain silos & feed storage

Nitrogen and CO₂ atmospheres can be created and monitored in a targeted way – for inerting, storage control or atmospheric pest control.

Gas supplyautomatically controllable

Alarmsautomatic

Custom solution

Diving technology

Heliox, Trimix and other defined gas mixtures can be produced and monitored reproducibly. Individual gas supply systems for hyperbaric chambers are also possible.

Multi-gas mixtureflexibly and freely configurable

Measuring rangeppm to %

Custom solution

Laser cutting

Cutting and assist gases can be mixed as needed and monitored for pressure, flow and composition.

Mixing rangeppm to %

Flow rateup to 5,000 ln/min

This is where GASYCO engineering begins

Some gas processes are too complex for standard solutions. When several gases have to be controlled precisely, corrosive media handled safely, variable reference pressures taken into account or downstream compressors integrated into the control strategy, it takes more than a device from the catalogue. This is exactly where GASYCO engineering begins.

We develop individual gas management systems tailored exactly to your application, your process conditions and your safety requirements. From precise gas mixing and pressure control through analysis, inerting and filling to intelligent monitoring and automated control, the result is solutions that are technically well thought out, industrial-grade and reliable in the long term. We combine high-quality components, our own control logic and personal technical advice – from the first idea to the operational system.

Possible fields of application

Where GASYCO custom solutions play to their strengths.

A selection of possible fields of application – with the requirements that matter in each case and the technical solutions with which we meet them. Every system is based on proven GASYCO components and is tailored to your application together with you.

Space

The purest atmospheres for manufacturing, testing and qualification.

Mixing and measuring rangeppm to %

Residual moisturefrom 0.1 ppm

In space, the gas atmosphere decides quality and reliability – in the manufacture of satellite components as well as in test benches and development laboratories. Even traces of oxygen or moisture can affect sensitive materials, electronics or adhesive bonds.

GASYCO systems enable controlled inerting, supply process gases precisely and monitor residual oxygen and residual moisture down to the ppm range. Every measured value is documented without gaps. This creates reproducible conditions for manufacturing, testing and development – with evidence that stands up to strict audits.

Typical uses

Satellite and component manufacturing
Inerting in cleanrooms and gloveboxes
Test benches and environmental simulation
Leak testing with defined test gases
Monitoring of residual moisture and residual oxygen

Matching technical solutions

Complex multi-gas control

Aviation

Fill oxygen cylinders yourself – even the ones hardly anyone else fills.

Pressure controlautomatic

Data loggingintegrated

Oxygen cylinders for the cockpit, cabin and emergency supply are often small and made of plastic or composite material in aviation. Many gas suppliers often do not fill precisely these cylinders – operators depend on long journeys, exchange systems or waiting times.

GASYCO develops automated filling systems with which you fill these cylinders yourself, right on site. Pressure, flow and the filling sequence are regulated reproducibly, gentle filling curves protect the cylinder material, and integrated data logging records every process – independent of the gas supplier and without transport to the filling plant.

Typical uses

Small plastic and composite cylinders
Filling directly in the hangar, at the airport or at the base
Gentle, pressure-controlled filling sequences
Filling records for maintenance and audit
Safety shutdown on limit violation

Matching technical solutions

Pressure-controlled cylinder filling

3D printing

Shielding gas and chamber atmosphere for additive manufacturing.

Mixing and measuring rangeppm to %

Flow rate0–5,000 ln/min

Whether laser sintering in a powder bed or wire arc additive manufacturing (WAAM) – the quality of additively manufactured metal parts depends directly on the shielding gas atmosphere. Residual oxygen and moisture influence microstructure, porosity and mechanical properties.

GASYCO supplies shielding gases and gas mixtures for all 3D printing processes in a targeted way and monitors residual oxygen and moisture continuously – in the gas supply as well as directly in the build chamber. Deviations are reported immediately and all values are documented. This makes build processes stably reproducible and parts safe to qualify.

Typical uses

Laser sintering and powder bed fusion
WAAM and deposition welding
Monitoring of the chamber atmosphere
Mixtures such as argon-helium as required

Matching technical solutions

Precise mixtures under challenging boundary conditions

Precise mixtures under challenging boundary conditions

Microelectronics

Stable process conditions down to the trace range.

Measuring rangeppm to %

Residual moisturefrom 0.1 ppm

In semiconductor and electronics manufacturing, processes react sensitively to the smallest fluctuations in the gas atmosphere. Forming gases, process gases and inerting must be exactly right – batch after batch.

We mix forming gases such as nitrogen-hydrogen mixtures precisely on site, control inert gases as needed and monitor residual oxygen and residual moisture down to the trace range. This creates stable conditions for soldering, bonding and annealing and reduces rejects caused by oxidation.

Typical uses

Forming gas for soldering and annealing processes
Inerting of furnaces and gloveboxes
Trace measurement of O₂ and H₂O
Supply of cleanroom processes

Matching technical solutions

Precise mixtures under challenging boundary conditions

Art, stage & events

Floating installations, show effects and protected works of art.

Mixing ratiosfreely configurable

Monitoringcontinuous and documented

Art and stage place unusual demands on gas technology. Floating installations need filling gases with exactly calculated buoyancy, show effects have to work reliably at the right moment, and delicate works in display cases and storage depots need an atmosphere that protects them for years.

We mix helium and helium mixtures so that objects float exactly where they should – reproducibly for every performance and directly on site, without bottlenecks in ready-made mixtures. We dose effects gases precisely, controllably and also for mobile use.

For museums and collections we create and monitor defined atmospheres that prevent oxidation and pest infestation, and document the conditions continuously.

Typical uses

Balloon gases for stage installations
Stage and show effects
Trade fairs, events and film production
Weather and research balloons
Low-oxygen display cases and storage depots

Matching technical solutions

Grain silos & feed storage

Controlled atmospheres for safe storage.

Gas supplyautomatically controllable

Alarmsautomatic

Grain, seed and animal feed are valuable – and vulnerable to pests, mould and fire. Atmospheres of nitrogen or CO₂ protect the goods without chemical residues.

GASYCO systems create the desired atmosphere in a targeted way, readjust the gas supply automatically and monitor oxygen and CO₂ content continuously. If a limit is exceeded or not reached, the system raises the alarm immediately. This allows inerting, storage control and atmospheric pest control to be implemented safely and verifiably.

Typical uses

Inerting of silos for fire protection
Residue-free pest control
Storage under controlled atmosphere
Remote monitoring of several stores

Matching technical solutions

Precise mixtures under challenging boundary conditions

Diving & breathing gases

Breathing gas mixtures you can rely on.

Multi-gas mixtureflexibly and freely configurable

Measuring rangeppm to %

In technical and professional diving, breathing gases are vital. Heliox, Trimix or Nitrox must correspond exactly to the planned composition – even small deviations endanger safety.

Our systems produce defined gas mixtures reproducibly from individual gases and monitor the composition continuously. Every mixture is documented and verifiable. We also develop individual gas supply systems for hyperbaric chambers.

Beyond diving, we also mix oxygen, nitrogen, helium and other gases exactly to specification – for example for altitude and climate simulation or controlled atmospheres in experiments – and monitor the oxygen content continuously.

Typical uses

Heliox, Trimix and Nitrox mixtures
Filling stations for dive centres
Gas supply for hyperbaric chambers
Altitude and climate simulation
Analysis and record of every mixture

Matching technical solutions

Pressure-controlled cylinder filling

Precise mixtures under challenging boundary conditions

Laser cutting

The right cutting gas for every material.

Mixing rangeppm to %

Flow rateas standard up to 5,000 ln/min, more on request

In laser cutting, cutting and assist gases determine cut quality, speed and cost. Nitrogen, oxygen or targeted mixtures have a direct effect on edge quality, oxidation and burr formation.

GASYCO mixes cutting gases as needed directly at the machine and monitors pressure, flow and composition continuously – even at high volume flows. This makes it possible to optimise mixtures for each material and sheet thickness, reduce gas consumption and ensure consistent cutting results.

Typical uses

Nitrogen-oxygen mixtures for each material
Supply of several laser systems
Monitoring of pressure and composition
Less gas consumption per cut

Matching technical solutions

Complex multi-gas control

Energy technology

Gas supply for fuel cells, electrolysis and power-to-gas.

Number of gasesunlimited

Safetyup to SIL 3

New energy technologies are developed and tested with gas: fuel cells need defined hydrogen and air mixtures, electrolysers a monitored product gas quality, power-to-gas plants exact blending into the grid.

Gas analysis is particularly in demand in electrolysis: the oxygen and hydrogen sides are monitored separately – each for traces of the other gas. If the hydrogen content in the oxygen or the oxygen content in the hydrogen rises, this is an early signal of membrane wear or leaks and a safety-relevant measured value, long before critical concentrations are reached.

GASYCO supplies mixing systems with any number of gas channels, analysers for ongoing quality control and – where necessary – safety-related monitoring up to SIL 3. This allows test benches, pilot plants and series processes to be operated safely, precisely and with full documentation.

Typical uses

Fuel cell test benches
Hydrogen blending and power-to-gas
H₂ in O₂ and O₂ in H₂ in electrolysis
Simulation of fuel gas qualities

Matching technical solutions

Precise mixtures under challenging boundary conditions

Precise mixtures under challenging boundary conditions

Medical technology

Test gases and integrated gas mixing for medical devices.

Measuring rangeppm to %

Documentationcomplete

Ventilators, anaesthesia systems and gas sensors have to be tested and calibrated with exactly defined gas mixtures in development, manufacturing and service. Every test must be reproducible and verifiable.

Instead of numerous premixed test gas cylinders, GASYCO systems generate the required concentrations directly at the test station – precisely, quickly switchable and with full documentation of every test step.

For incubator manufacturers, we also offer our gas mixers as an OEM variant. In CO₂ and multi-gas incubators, the integrated mixer controls CO₂, O₂ and N₂ precisely to the desired atmosphere – stable, quickly re-established after the door is opened and fully recorded. We adapt mechanics, electronics and interfaces to your device, under your brand on request.

Typical uses

OEM gas mixer for incubators
Atmospheres of CO₂, O₂ and N₂
End-of-line testing of medical devices
Calibration of gas sensors
Test records for approval and audit

Matching technical solutions

OEM integration into your devices