FusionFlow™ Gas Blending Products for R&D and Industrial Applications
Highly customizable gas mixing platforms tailored to almost any industrial and laboratory operation
Alicat® Scientific’s FusionFlow systems are turnkey, all-in-one gas blending solutions built for speed, flexibility, and accuracy. Driven by Alicat’s proprietary MixModule command and control architecture, FusionFlow delivers seamless control of multiple mass flow controllers, enabling precise gas mixing across a wide range of research and industrial applications—from established processes to cutting-edge experimental work.
What is FusionFlow gas blending?
A combination of the latest technologies
FusionFlow products operate on the concept of dynamic gas mixing, the process of creating and controlling gas mixtures whose composition can change in real time. Unlike traditional "fixed-ratio" gas blending systems, where setpoints are static and mixtures are manually adjusted, Alicat gas blending systems allow for fully variable ratios that can be altered automatically, on demand, or even continuously over time.
High speed architecture and mixture control
At the heart of the FusionFlow product line is the MixModule, a command and control unit; the busy hub of mixing logic, user input, and real-time control of the various mass flow controllers (MFCS). The MixModule uses a high-speed control architecture to deliver precise, responsive management across all gas channels, resulting in tightly regulated flow and pressure control of final mixtures.
MixModule’s advanced control performance is powered by a proprietary embedded firmware package, that enables instant, lag-free adjustments that outperform software-only mixers. A dedicated quad-core processor manages higher-level functions, including the touchscreen interface, scripting, and automation control.
This division of responsibilities between the MixModule and the system processor gives FusionFlow its hallmark combination of speed, precision, and reliability.
Unmatched flexibility
The MXM gas blender and IMX industrial gas mixer allow users to program step changes or linear transitions between preset gas mixtures, enabling smooth composition changes over defined time intervals. This functionality is ideal for applications that require repeatable conditions or automated calibration cycles, allowing mixtures to shift seamlessly while flow remains continuous.
The MXM model supports up to 10 independent gas channels in standalone configurations, and the IMX supports up to 4 channels. Both systems allow multiple gases to be blended simultaneously with exceptional accuracy. Channels can also be configured for the same gas at different flow capacities, providing a high dynamic range of control—offering both fine precision and high-volume output when needed.
Precision and reliability
Every FusionFlow device incorporates self-evaluating logic that constantly verifies mixture accuracy. If the target composition cannot be achieved, the system automatically alarms and halts operations to prevent errors. The result is consistent, traceable gas mixing, trusted by some of the largest gas utility distributors in the United States.
Automation and connectivity
As an IoT-ready instrument, the FusionFlow MXM integrates directly into laboratory or industrial networks for full remote control, scripting, and data logging. Real-time gas mixing demands real-time control, and the FusionFlow delivers it.
Alicat’s family of FusionFlow instruments
FusionFlow MXM gas blending system
Intellegent, percent-level gas blenders with 4 form-factors to accommodate wide-ranging installation challenges, plumbing infrastructure, and variable flow requirements
Features
- Total flows of 0 – 20 SCCM to 0 – 120,000 SLPM depending on MFC configuration and form factor (2 – 10 devices)
- High resolution touchscreen HMI for data and blending control
- Blend up to 10 gas streams, using pure or premixed feed sources
FusionFlow IMX industrial gas mixer
An industrial-focused, high flow gas mixer with ease of use at its core. Ideal for repetitive, single-recipe, 24/7 operations
Features
- Total flows of 0 – 20 SLPM to 0 – 3200 SLPM are available depending on MFC configuration (2 – 4 devices)
- Simple, 7-button membrane control pad, with color TFT display screen
- Blend up to 4 gas streams, using pure or premixed feed sources
Customer stories
FusionFlow IMX and MXM gas blending products are built with customization at heart. Whether you’re working with variable flow rates or different gases, FusionFlow adapts to your process. Here are some industries putting our products to work in real-world applications:
Low Methane Flare Gases
University of Minnesota (UMN) is working with Department of Energy’s Advanced Project Research Agency for Energy (APRA-E) aiming to develop a plasma‑assisted in‑situ flare gas reforming, ignition, and flame stabilization system for small (typical tip...
Carbon Cycle Sulfide Tracer Model
The University of Arizona’s Meredith lab is working to form climate models at parts‑per‑trillion (ppt) dilution levels to better understand the delicate balance of carbon cycles and their effect in climate change. By validating carbonyl sulfide (OCS) as a...
Gas Sensor Calibration Basics
Whether developing a gas sensor and testing its sensitivity and repeatability, or calibrating a sensor for quality compliance, you likely will need a traceable reference test gas. Manufacturers of sensors and process regulators require calibration of sensors...
Welding Shield Gas Arc Welding
By Patricio Mendez and Goetz DappPrecision in shield gas mixing can optimize weld quality, efficiency, and safety. Understanding the impact of shield gas composition as it relates to weld characteristics can lead to innovations that reduce fume emissions,...
“Great gas mixing solutions, everything hit our requirements. The FusionFlow team has unlocked completely new opportunities in R&D and we look forward to working on more projects with them.”
— Jacob Goldberg – Osmo Systems
Supported applications
By working closely with our customers, Alicat has fostered a collaborative environment to help build custom solutions for critical processes, here are a few of the industries.
Modified atmosphere food packaging
Benefits of FusionFlow IMX for packaging lines & compliance
- Accurate multi-gas mass flow measurement keeps your blends on-the-mark
- Fast 25ms control response neutralizes pressure fluctuations
- On-site blending saves money typically spent on bottled mixes
- All-in-one configuration makes for easy gas blending without a computer
Bioreactor and biotechnology laboratories
Benefits of FusionFlow MXM for batching and research
- Scheduling control with built in calendar functions to match ideal growth conditions
- Dynamically change and create gases for custom experiments
- Low flow capabilities for pulse modulated sparging
- Linear interpolation allows smooth change between gas mixes
Glove-box atmosphere testing
Maintaining stable gas pressure in a glove-box is already challenging enough. When custom mixed-gas glove-box atmospheres are also required, FusionFlow MXM can deliver precise molecular ratios while maintaining the internal box pressure. In this “active pressure control mode”, the MXM provides the needed gas composition and the required total system pressure to the test chamber. Pressure limits can also be set to protect large enclosures from over-pressurization.
Benefits of FusionFlow MXM for atmospheric and space science
- Active pressure control maintains stable internal environments during use
- Precise gas blending ensures accurate custom atmosphere compositions
- Adjustable pressure limits safeguard against overpressure conditions
Research and development
Benefits of FusionFlow MXM for research laboratories
- Multiple gas delivery modes enable conditional start/stop control
- Compatible with pre-mixed or custom feed sources for ppm and ppb accuracy
- Extensive automation and remote operation through a network-connected browser
- Stable flow and pressure control support long-duration and low-leak testing environments
Dynamic gas blending with precise mass flow control
- NIST-traceable accuracy as good as ± 0.6% of targeted mix percentage
- Laminar MFC-based percent-level mixing for quick startup and verbose data logging
- Onboard library of 49 selectable gas calibrations with select support for corrosives & refrigerants
- Alternative build options and remote access command & control
- Advanced automation at your fingertips through scheduling recipes, preset mixes, and events
“…worked great for our needs. It was very easy to use/operate and was better than us just purchasing two Alicat flow controllers and making adjustments on our own. The software was great for showing real time gas mixtures, pressures, and flows.”
— MXM customer
The Fusion Flow Story
Created as a division of Alicat Scientific, Inc., Fusion Flow Technologies was born in 2019 to provide turn-key products to Alicat’s customers looking for all-in-one gas mixing solutions, instead of spending valuable resources engineering their own solution. The division’s services were originally hosted on FusionFlowTechnologies.com, before being integrated into Alicat Scientific’s product line as FusionFlow™ in 2025.
The FusionFlow team began building fully custom, process-specific units, and developed repeatable models that retained the best qualities of the custom designs. This led to the creation of their flagship offerings—the MXM gas blending system, and the IMX industrial gas mixer.
Every MXM is driven by a master control unit known as the MixModule, and a proprietary firmware package at its core. These allow the device to make advanced measurements, communications, and calculations, at Alicat speeds. These models became available in various form factors ranging from table-top installations to rack-mount control interfaces, able to accurately combine up to 10 gases at once while delivering the mixture at either pressure or flow priorities. Throughout its history, FusionFlow has relied on Alicat’s high-speed mass flow and pressure instruments to achieve exceptional precision and industry-leading accuracy.
Looking ahead, FusionFlow will continue advancing the MXM and IMX, while pioneering refined blending technologies to serve an expanding range of industries.
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Your flow rate, pressure, and choice of gas can all affect which Alicat instruments work for your application.
Our Applications Engineers can answer your questions and help you find the best option.
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