Manufacturing HELIOS
Machining, welding, and assembly of the forge, mixer, cart, and enclosure.
Manufacturing HELIOS
Enclosure fabrication
The photographs document the cart, sheet-metal panels, door openings, and enclosure assembly.
Building the enclosure
Mixer manufacturing
The mixer is designed around 304 stainless steel for corrosion resistance in a wet, outdoor shop environment. The internal nozzle, chamber, and receiver geometry are machined to establish the concentric flow passages and gas-metering surfaces. Turning produces the circular bores and tapers; milling and drilling produce the ports and locating features. The outlet uses machined sections with a continuous internal transition, fitted and TIG-welded into the stainless pipe assembly. Alignment and smooth internal joints matter because steps or offsets can disturb the jet, increase pressure loss, and change entrainment.
Shop fabrication
Welding and machining work in the shop, alongside the fabrication documented above.
Welding the steel frame in the shop
Welding the frame joints
Turning at the metal lathe
Enclosure assembly
The frame, panels, mounting points, and control enclosure progress from fabricated parts to an assembled cart.
Machining
Turning and CNC milling establish the mixer components, bores, and mounting features before assembly.
